PC78UU-6 Nho

STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
PC78US-6 (with blade) Serial No.: 4001 – 5500
PC78UU-6 (with blade) Serial No.: 22832 – 23500
Model: LPD45 + 45
P1 : Pump discharge PD2 : Pump drain (plug)

P2 : Pump discharge PDA: Air bleeder
P3 : Gear pump discharge PEN: Control pressure pickup port
P4 : Pilot pump discharge PGS: Gear pump suction
P5 : Gear pump pressure pickup port PLS : LS pressure input (From control valve)
PD : Drain PPT : PTO oil filler
PM : PC mode changeover pressure pickup port PS1 : Main pump suction
P1T : Travel deviation adjustment orifice PEPC: EPC main pressure pickup port
P2T : Travel deviation adjustment orifice PPLS : Pump pressure input (From control valve)
PC78US-6 10-55
(10)
PC78US-6 (without blade) Serial No.: 4001 – 5500

Model: LPD45 + 45

P2 : Pump discharge PEN: Control pressure pickup port
P4 : Pilot pump discharge PLS : LS pressure input (From control valve)
PD2 : Pump drain (plug)
10-56 PC78US-6
(10)
T : Drain PD2 : Drain (Plug)

P1 : Pump discharge PDE: EPC drain
P2 : Pump discharge PEN: Control pressure input
P3 : Gear pump pressure input PPT : PTO oil filler
PD : Drain PS1 : Pump suction
PH : Pump shuttle PEPC: EPC main pressure pickup port
PAV : Pump average pressure
PC78US-6 10-57
(10)
1. Shaft
2. Flange
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Servo piston
10. Oil seal
10-58 PC78US-6
(10)
PDE: EPC drain

1. EPC valve
PC valve LS valve
T: Drain 4. Retainer PE: Control piston pressure 14. Seat
P3: Gear pump pressure input 5. Seat PH: Pump shuttle pressure 15. Spring
PH: Pump shuttle pressure 6. Spool PLS: LS pressure input 16. Seat
PAV: Pump average pressure 7. Sleeve PPL: PC valve output pressure 17. O-ring
PPL: PC valve output pressure 8. Piston PPLS: LS pump pressure input 18. Backup ring
PEPCOUT: EPC output pressure 9. Seal 19. Nut
10. Piston 12. Spool 20. Plug
2. Lever 11. Plug 13. Plug
3. Spring
PC78US-6 10-59
(10)
PC78US-6 (with blade) Serial No.: 5501 – 6500

PC78UU-6 (with blade) Serial No.: 23501 and up
Model: LPD45 + 45

10-60 PC78US-6
(10)
T : Drain PAV : Pump average pressure

P1 : Pump discharge PD2 : Drain (Plug)
P3 : Gear pump pressure input PEN: Control pressure input
P5 : Gear pump pressure pickup port PPT : PTO oil filler
PC78US-6 10-61
(10)
PC78US-6 (without blade) Serial No.: 5501 – 6500

Model: LPD45 + 45

10-62 PC78US-6
(10)
T : Drain PD3 : Drain

PH : Pump shuttle PS1 : Pump suction
PAV : Pump average pressure PEPC: EPC main pressure pickup port
PD2 : Drain (Plug)
PC78US-6 10-63
(10)
1. Shaft
2. Flange
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Servo piston
10. Oil seal
10-64 PC78US-6
(10)
PDE: EPC drain

1. EPC valve
PC valve LS valve
3. Spring
PC78US-6 10-65
(10)
PC78US-6 (with blade) Serial No.: 6501 and up

Model: LPD45 + 45

10-66 PC78US-6
(10)
T : Drain PAV : Pump average pressure

P1 : Pump discharge PD2 : Drain (Plug)
P3 : Gear pump pressure input PEN: Control pressure input
P5 : Gear pump pressure pickup port PPT : PTO oil filler
PC78US-6 10-67
(10)
PC78US-6 (without blade) Serial No.: 6501 and up

Model: LPD45 + 45

10-68 PC78US-6
(10)
T : Drain PD3 : Drain

PH : Pump shuttle PS1 : Pump suction
PAV : Pump average pressure PEPC: EPC main pressure pickup port
PD2 : Drain (Plug)
PC78US-6 10-69
(10)
1. Shaft
2. Flange
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Servo piston
10. Oil seal
10-70 PC78US-6
(10)
PDE: EPC drain

1. EPC valve
PC valve LS valve
3. Spring
PC78US-6 10-71
(10)
Function • The oil in each cylinder of cylinder block (7) can

• This pump converts the revolution and torque of be drawn and discharged through valve plate (8).
the engine transmitted to its shaft into hydraulic
energy and discharges hydraulic oil according to
the load.
• The discharge can be changed by changing the
swash plate angle.
Structure
• Cylinder block (7) is supported on shaft (1)
through spline a. Shaft (1) is supported on the
front and rear bearings.
• The end of piston (6) is a concave sphere, which
holds shoe (5) as a spherical bearing.
• Rocker cam (4) has plane A. Shoe (5) is kept
pressed against plane A and slid circularly.
Rocker cam (4) is supported on flange (2) and
ball (12) fixed to the case and slides on the
formed static pressure bearing and high-pres-
sure oil.
• Piston (6) moves axially and relatively in each
cylinder of cylinder block (7).
• Cylinder block (7) revolves relatively against
valve plate (8), sealing the hydraulic oil. The
hydraulic pressure on the revolving surface of
the cylinder block is balanced properly.
10-72 PC78US-6
(10)
Operation • If center line X of rocker cam (4) is in the direc-

tion of the axis of cylinder block (7) (Swash plate
1. Operation of pump angle = 0), the difference between volumes E
and F in cylinder block (7) is 0 and oil is not
• Shaft (1) and cylinder block (7) revolve together sucked or discharged (The swash plate angle is
and shoe (5) slides on plane A. As rocker cam not reduced to 0 actually, however).
(4) slants around ball (12) at this time, angle ( ) • In short, swash plate angle ( ) is in proportion to
between the center line X of rocker cam (4) and the discharge of the pump.
axis of cylinder block (7) changes. Angle ( ) is • The number of holes on cylinder block (7) is
called the swash plate angle. even 10 and every second one of them is fitted
to 2 grooves of valve plate (8). The quantity of
the oil equivalent to 5 pistons is discharged to
each of P1 and P2.
• If the angle between the center line X of rocker

cam (4) and the axis of cylinder block (7) is a,
plane A works as a cam for shoe (5).
• Accordingly, piston (6) slides inside cylinder
block (7) and makes difference between volumes
E and F in cylinder block (7) and the oil is drawn
and discharged by the difference.
• In short, if cylinder block (7) revolves and volume
of chamber E is reduced, the oil is discharged.
On the other hand, the volume of chamber F is
increased and the oil is sucked. (The figure
shows the end of suction process of chamber F
and the end of discharge process of chamber E.)
PC78US-6 10-73
(10)
2. Control of discharge LS valve

• If swash plate angle ( ) is increased, the differ- Function
ence between volumes E and F, or discharge Q, • The LS valve controls the discharge of the pump
is increased. Swash plate angle ( ) is changed according to the stroke of the control lever, or the
with servo piston (11). demand flow for the actuator.
• Servo piston (11) is reciprocated linearly by the • The LS valve calculates the demand flow for the
signal pressure of PC and LS valves. This linear actuator fr om differential pr essure PLS
motion is transmitted to rocker cam (4) sup- between inlet pressure PPLS and outlet pres-
ported on flange (2) through ball (12). Then, sure PLS of the control valve, and controls dis-
rocker cam (4) slides in the revolutionary direc- charge Q of the main pump.
tion. (PPLS is called the LS pump pressure, PLS
the LS pressure, and PLS the LS differential
pressure.)
• That is, the discharge of the pump is controlled
according to the demand flow for the actuator by
the following method; The pressure loss made
when the oil flows through the opening of the
control valve spool (LS differential pressure
PLS) is sensed and discharge Q of the pump is
so controlled that the pressure loss will be con-
stant.
• The LS valve receives main pump discharge
pressure PP, LS pump pressure (PPLS), and LS
pressure PLS. The relationship between the LS
differential pressure ( PLS) and pump dis-
charge Q changes as shown below.
10-74 PC78US-6
(10)
PC valve • At this time, ports F and G of the LS valve are

connected to each other. As a result, the pres-
Function sure in port J becomes drain pressure PT and
• The PC valve limits the oil flow to a certain level servo piston (6) moves to the left.
(according to the discharge pressure) even if the • Consequently, the pump discharge is increased.
stroke of the control valve is increased so that • As servo piston (6) moves, lever (1) moves to the
the horsepower absorbed by the pump will not left and spring (2) expands and its spring load is
exceed the engine horsepower, as long as pump decreased. Consequently, spool (3) moves to
discharge pressure PP is high. That is, the PC the left to break the connection of ports C and D,
valve performs constant-horsepower control. and then pump discharge ports B and C are con-
• In other words, the PC valve decreases the nected.
pump discharge when the load is increased and • As a result, the pressure in port C rises and the
the pump discharge pressure rises and piston pressure is increased and servo piston (6)
increases it when the pump discharge pressure stops moving to the left.
lowers.
• This pump has 2 discharge openings and the (3) When pump pressure PAVE is high
average of discharge pressures P1 and P2 at • The pressure of spool (4) is increased and spool
those openings is sensed. (3) is a little to the left (Fig. 2 and Fig. 5). At this
The average of P1 and P2 is called the PAVE. time, ports C and B are connected to each other
The relationship between this average and pump and the pressure in the LS valve is pump pres-
discharge (discharge from the 2 discharge open- sure PP.
ings) is shown below. • At this time, ports F and G of the LS valve are
connected to each other. As a result, the pres-
sure in port J becomes pump pressure PP and
servo piston (6) moves to the right.
• Consequently, the pump discharge is decreased.
• As servo piston (6) moves, lever (1) moves to the
right and spring (2) is compressed and its spring
load is increased. Consequently, spool (3)
moves to the right to break the connection of
ports C and B, and then drain pressure ports D
and C are connected.
• As a result, the pressure in port C lowers and the
piston pressure is decreased and servo piston
(6) stops moving to the right.
• Accordingly, the stopping position (= pump dis-
charge) of servo piston (6) is decided by the
Operation position where the pressure caused by pressure
1. PC78UU, 78US-6 (With blade) PP applied to spool (4) is balanced with the force
of spring (2) applied through spool (3) (Fig. 3 and
(1) Function of spring Fig. 6).
• The spring load of spring (2) at the PC valve is
decided by the position of the swash plate. (4) When swing gear pump pressure rises/low-
• If servo piston (6) moves to the right, spring (2) is ers
compressed through lever (1) and its spring load • The pressure of spool (4) changes and the pump
changes. The spring constant of this spring discharge changes similarly to the case where
changes to 2 levels. the PAVE rises/lowers.
• The PC-EPC valve changes the output pressure
(2) When pump pressure PAVE is low according to the input current from the controller,
• The pressure of spool (4) is decreased and spool then the pressure of spool (5) changes and the
(3) is a little to the right (Fig. 1 and Fig. 4). At this pump discharge changes similarly to the case
time, ports C and D are connected to each other where the PAVE rises/lowers.
and the pressure in the LS valve is drain pres-
sure PT.
PC78US-6 10-75
(10)
When load is light
When load is heavy
10-76 PC78US-6
(10)
When balanced
2. PC78US-6 (Without blade)

• Although the swing gear pump is not mounted, the theory of operation of this model is the same as that of
the machine equipped with the swing gear pump.
When load is light
PC78US-6 10-77
(10)
When load is heavy
When balanced
10-78 PC78US-6
(10)
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
Outline
a The control valves of the following types are set.
PC78US-6 • Blade-less, without service valve

• Blade-less, with 1 service valve
• Blade-less, with 2 service valve
• With blade, without service valve
• With blade and 1 service valve
• With blade and 2 service valve
PC78UU-6 • Without service valve

• 1 service valve
• 2 service valve
a Since each service valve is of add-on type, it can

be added or removed later.
1. PC78US-6 blade-less and with 1 service

valve
(1) Outside view
A1: To swing motor PT: To travel pressure switch

A2: To left travel motor TB: To tank
A3: To right travel motor TC: To oil cooler
A4: To boom cylinder bottom TS: To tank
A5: To arm cylinder head PA1: From swing right PPC valve
A6: To bucket cylinder head PA2: From left travel reverse PPC valve
A7: To attachment 1 PA3: From right travel reverse PPC valve
B1: To swing motor PA4: From boom raise PPC valve
B2: To left travel motor PA5: From arm out PPC valve
B3: To right travel motor PA6: From bucket dump PPC valve
B4: To boom cylinder head PA7: From service 1 PPC valve
B5: To arm cylinder bottom PB1: From swing left PPC valve
B6: To bucket cylinder bottom PB2: From left travel forward PPC valve
B7: To attachment 1 PB3: From right travel forward PPC valve
BP: From boom RAISE PPC valve PB4: From boom lower PPC valve
LS: To pump LS valve (LS pressure input) PB5: From arm in PPC valve
P1: From main pump PB6: From bucket curl PPC valve
P2: From main pump PB7: From service 1 PPC valve
PP: To pump LS valve (Pump pressure input) TSW: To swing motor
PS: From swing holding brake reset solenoid valve
10-80 PC78US-6
(10)
(PC78US-6 blade-less and with 1 service valve)
PC78US-6 10-81
(10)
(2) Sectional view

Serial No.: 4001 – 6500
(1/4)
10-82 PC78US-6
(10)
Serial No.: 6501 and up

(1/4)
PC78US-6 10-83
(10)
1. Suction valve (Left travel) 29. Pressure compensation valve F (Swing)

2. Suction valve (Right travel) 30. Pressure compensation valve F (Left travel)
3. Main relief valve 31. Pressure compensation valve F (Right travel)
4. Suction valve (Boom bottom) 32. Pressure compensation valve F (Boom)
5. Suction valve (Arm head) 33. Pressure compensation valve F (Arm)
6. Suction valve (Bucket head) 34. Pressure compensation valve F (Bucket)
7. Suction valve (Attachment) 35. Pressure compensation valve F (Attachment)
8. Safety valve 36. Pump pressure pickup plug (P2)
9. Suction valve (Attachment) 37. LS pressure pickup plug (LS3)
10. Suction valve (Bucket bottom) 38. Pressure compensation valve R (Attachment)
11. Suction valve (Arm bottom) 39. Pressure compensation valve R (Bucket)
12. Suction valve (Boom head) 40. Pressure compensation valve R (Arm)
13. Lift check valve 41. Pressure compensation valve R (Boom)
14. Cooler bypass valve 42. LS bypass plug (LS2)
15. Suction valve (Right travel) 43. Logic valve
16. Suction valve (Left travel) 44. Spool (Pump merge-divider valve)
17. Spool (Swing) 45. Pressure compensation valve R (Right travel)
18. Spool (Left travel) 46. Pressure compensation valve R (Left travel)
19. Spool (Right travel) 47. Pressure compensation valve R (Swing)
20. Unload valve (P1) 48. Check valve (Attachment)
21. Unload valve (P2) 49. Check valve (Bucket)
22. Spool (Boom) 50. Check valve (Arm)
23. Spool (Arm) 51. Boom hydraulic drift prevention valve
24. Spool (Bucket) 52. Check valve (Boom bottom)
25. Spool (Attachment)
26. LS pressure pickup plug (LS2) F: Flow control valve
27. LS pressure pickup plug (LS1) R: Pressure reducing valve
28. Spool (LS selector)
10-84 PC78US-6
(10)
Unit: mm
No. Item Criteria Remedy
Basic dimensions Allowable limit

Free length x
Installed Installed Installed
Lift check Outside Free length
53 length load load
valve spring diameter
59.6 N 47.7 N
58.1 X 17.0 36 —
{5.8 kg} {4.64 kg}
73.5 N 58.8 N
54 Cooler bypass valve spring 34.5 X 17.7 25 —
{7.5 kg} {6.0 kg}
28.3 N 22.6 N
55 Spool return spring (Swing) 29.2 X 17.5 28.5 —
{2.89 kg} {2.31 kg}
22.6 N 18.1 N
56 Spool return spring (Travel) 29.0 X 17.5 28.5 —
{2.3 kg} {1.84 kg}
43.1 N 34.5 N
57 Spool return spring (Arm in) 41.1 X 19.3 40.5 —
{4.4 kg} {3.52 kg}
Spool return spring 34.3 N 27.4 N
58 41.1 X 19.3 40.5 —
(Work equipment) {3.5 kg} {2.8 kg}
54.9 N 43.9 N
59 Spool return spring (Arm out) 42.3 X 19.2 40.5 —
{5.6 kg} {4.49 kg}
129 N 103 N
60 Unload valve spring 40.9 X 15.1 33.5 — If damaged or
{13.2 kg} {10.6 kg}
deformed,
11.2 N 8.96 N replace spring.
61 LS selector valve spring 16.6 X 13.0 13 —
{1.14 kg} {0.91 kg}
Pressure compensation valve 7.45 N 5.96 N
62 15.4 X 6.0 8 —
spring {0.76 kg} {0.61 kg}
Pump merge-divider valve 49.0 N 39.2 N
63 33.2 X 14.2 22.5 —
spool return spring {5.0 kg} {4.0 kg}
Pressure compensation valve 27.7 N 22.2 M
64 30.9 X 5.2 20 —
spring {2.82 kg} {2.26 kg}
65 28.0 X 14.4 14.5 —
spring {1.4 kg} {1.12 kg}
66 33.4 X 14.4 21.5 —
67 20.0 X 8.4 12 —
68 23.0 X 8.4 15 —
3.92 N 3.14 N
69 Check valve spring 12.3 X 11.4 10.5 —
{0.4 kg} {0.32 kg}
3.92 N 3.14 N
70 Check valve spring 27.2 X 6.9 22 —
{0.4 kg} {0.32 kg}
PC78US-6 10-85
(10)
Serial No.: 4001 – 6500

(2/4)
10-86 PC78US-6
(10)

(2/4)
PC78US-6 10-87
(10)
1. Spool (LS selector)

2. Spool (Swing)
3. Pressure compensation valve R (Swing)
4. Pressure compensation valve F (Swing)
5. Pressure compensation valve F (Left travel)
6. Suction valve (Left travel)
7. Spool (Left travel)
9. Pressure compensation valve R (Left travel)
10. LS bleed valve
11. Pressure compensation valve F (Right travel)
12. Suction valve (Right travel)
13. Spool (Right travel)
15. Pressure compensation valve R (Right travel)
16. Travel junction valve, LS bleed valve
17. Pump pressure pickup plug (P1)
18. Spool (Pump merge-divider valve)
19. Unload valve (P1)
20. Check valve (P1)
21. Cooler bypass valve
22. LS pressure pickup plug (LS1)
23. LS bypass plug (LS1)
24. Logic valve
F: Flow control valve

R: Pressure reducing valve
Unit: mm

Free length x
Outside Free length
25 Check valve spring length load load
diameter
If damaged or
1.96 N 1.57 N
21.9 X 5.0 15.8 — deformed,
{0.2 kg} {0.16 kg}
replace spring.
15.7 N 12.6 N
26 Travel junction valve spring 19.3 X 7.5 14 —
{1.6 kg} {1.28 kg}
2.26 N 1.81 N
{0.23 kg} {0.18}
10-88 PC78US-6
(10)
(3/4)
10-90 PC78US-6
(10)

2. Main relief valve
3. Check valve (P2)
4. Lift check valve
7. Pressure compensation valve F (Boom)
8. Suction valve (Boom bottom)
9. Boom hydraulic drift prevention valve
10. Suction valve (Boom head)
11. Spool (Boom)
12. Pressure compensation valve R (Boom)
13. Suction valve (Arm head)
14. Spool (Arm)
15. Suction valve (Arm bottom)
16. Pressure compensation valve R (Arm)
17. Pressure compensation valve F (Arm)
18. Suction valve (Bucket head)
19. Spool (Bucket)
20. Suction valve (Bucket bottom)
21. Pressure compensation valve R (Bucket)
22. Pressure compensation valve F (Bucket)
23. Suction valve (Attachment)
26. Pressure compensation valve R (Attachment)
27. Pressure compensation valve F (Attachment)
29. Safety valve
30. Pressure release plug

Unit: mm

Free length x
Outside Free length
diameter
If damaged or
2.26 N 1.81 N
13.0 X 6.5 9 — deformed,
{0.23 kg} {0.18}
replace spring.
Hydraulic drift prevention valve 11.2 N 8.96 N
33 16.6 X 13.0 13 —
spring {1.14 kg} {0.91 kg}
34 13.0 X 8.8 7.7 —
PC78US-6 10-91
(10)
(4/4)
10-92 PC78US-6
(10)

2. LS bleed valve
3. Check valve (Boom head)
4. Logic valve
Unit: mm

Free length x
Outside Free length
5 Check valve spring length load load If damaged or
diameter
deformed,
27.2 X 6.9 22 —
{0.4 kg} {0.32 kg}
5.5 N 4.4 N
6 Logic valve spring 11.0 X 6.2 9.5 —
{0.56 kg} {0.45 kg}
PC78US-6 10-93
(10)
2. PC78US-6 with blade and 1 service

valve
(1) Outside view
A1: To blade cylinder head

A2: To swing motor
A3: To left travel motor
A4: To right travel motor
A5: To offset cylinder head
A6: To boom cylinder bottom
A7: To arm cylinder head
A8: To bucket cylinder head
B1: To blade cylinder bottom
B2: To swing motor
B3: To left travel motor
B4: To right travel motor
B5: To offset cylinder bottom
B6: To boom cylinder head
B7: To arm cylinder bottom
B8: To bucket cylinder bottom
BP: From boom RAISE PPC valve
LS: To pump LS valve (LS pressure input)
P1: From main pump
P2: From main pump
P3: From gear pump
PP: To pump LS valve (LS pressure input)
PT: To travel pressure switch
TB: To tank
TC: To oil cooler
TS: To tank
PA1: From blade raise PPC valve
PA2: From swing right PPC valve
PA3: From left travel reverse PPC valve
PA4: From right travel reverse PPC valve
PA5: From offset right PPC valve
PA6: From boom raise PPC valve
PA7: From arm out PPC valve
PA8: From bucket dump PPC valve
PB1: From blade lower PPC valve
PB2: From swing left PPC valve
PB3: From left travel forward PPC valve
PB4: From right travel forward PPC valve
PB5: From offset left PPC valve
PB6: From boom lower PPC valve
PB7: From arm in PPC valve
PB8: From bucket curl PPC valve
TSW: To swing motor
10-94 PC78US-6
(10)
(PC78US-6 with blade and 1 service valve)
PC78US-6 10-95
(10)
(2) Sectional view

Serial No.: 4001 – 6500
(1/4)
10-96 PC78US-6
(10)

(1/4)
PC78US-6 10-97
(10)
1. Safety-suction valve (Blade head) 31. LS pressure pickup plug (LS1)

2. Suction valve (Left travel) 32. Pressure compensation valve F (Left travel)
3. Suction valve (Right travel) 33. Pressure compensation valve F (Right travel)
4. Main relief valve 34. Pressure compensation valve F (Boom)
5. Suction valve (Boom bottom) 35. Pressure compensation valve F (Arm)
6. Suction valve (Arm head) 36. Pressure compensation valve F (Bucket)
7. Suction valve (Bucket head) 37. Pressure compensation valve F (Attachment)
8. Suction valve (Attachment) 38. Pump pressure pickup plug (P2)
9. Safety valve 39. LS pressure pickup plug (LS3)
10. Suction valve (Attachment) 40. Pressure compensation valve R (Attachment)
11. Suction valve (Bucket bottom) 41. Pressure compensation valve R (Bucket)
12. Suction valve (Arm bottom) 42. Pressure compensation valve R (Arm)
13. Suction valve (Boom head) 43. Pressure compensation valve R (Boom)
17. Suction valve (Blade bottom) 47. Pressure compensation valve R (Right travel)
18. Gear pump relief valve 48. Pressure compensation valve R (Left travel)
19. Spool (Boom raise merge) 49. Check valve (Swing)
20. Spool (Blade) 50. LS bleed valve
21. Spool (Swing) 51. Travel junction valve, LS bleed valve
22. Spool (Left travel) 52. Check valve (Attachment)
23. Spool (Right travel) 53. Check valve (Bucket)
24. Unload valve (P1) 54. Check valve (Arm)
25. Unload valve (P2) 55. Boom hydraulic drift prevention valve
26. Spool (Boom) 56. Check valve (Boom bottom)
27. Spool (Arm) 57. Check valve (Blade)
28. Spool (Bucket)
29. Spool (Attachment) F: Flow control valve
30. LS pressure pickup plug (LS2) R: Pressure reducing valve
10-98 PC78US-6
(10)
Unit: mm

Free length x
Cooler bypass Outside Free length
58 length load load
73.5 N 58.8 N
34.5 X 17.7 25 —
{7.5 kg} {6.0 kg}
59 29.0 X 18.3 27.5 —
(Blade, swing) {9.1 kg} {7.28 kg}
22.6 N 18.1 N
60 Spool return spring (Travel) 29.0 X 17.5 28.5 —
{2.3 kg} {1.84 kg}
43.1 N 34.5 N
61 Spool return spring (Arm in) 41.1 X 19.3 40.5 —
{4.4 kg} {3.52 kg}
62 41.1 X 19.3 40.5 —
54.9 N 43.9 N
63 Spool return spring (Arm out) 42.3 X 19.2 40.5 —
{5.6 kg} {4.49 kg}
129 N 103 N
64 Unload valve spring 40.9 X 15.1 33.5 —
{13.2 kg} {10.6 kg}
Boom RAISE merge valve 11.2 N 8.96 N
65 16.6 X 13.0 13 —
spring {1.14 kg} {0.91 kg}
If damaged or
Pump merge-divider valve 49.0 N 39.2 N
66 33.2 X 14.2 22.5 — deformed,
replace spring.
67 30.9 X 5.2 20 —
spring {2.82 kg} {2.26 kg}
68 28.0 X 14.4 14.5 —
69 33.4 X 14.4 21.5 —
70 20.0 X 8.4 12 —
2.26 N 1.81 N
{0.23 kg} {0.18}
3.92 N 3.14 N
{0.4 kg} {0.32 kg}
3.92 N 3.14 N
{0.4 kg} {0.32 kg}
1.96 N 1.57 N
{0.2 kg} {0.16 kg}
136.41 N 109 N
75 Spool return spring (Boom) 41.13 X 19.3 38.5 —
{13.91 kg} {11.1 kg}
89.5 N 71.6 N
76 Spool return spring (Blade) 29.01 X 18.3 27.5 —
{9.1 kg} {7.3 kg}
PC78US-6 10-99
(10)
Serial No.: 4001 – 6500

(2/4)
10-100 PC78US-6
(10)

(2/4)
PC78US-6 10-101
(10)
1. Spool (Boom raise merge)

2. Gear pump relief valve
3. Safety-suction valve (Blade head)
4. Suction valve (Blade bottom)
5. Spool (Blade)
6. Check valve (Blade)
7. Spool (Swing)
8. Check valve (Swing)
14. LS bleed valve
27. Logic valve

Unit: mm

Free length x
Outside Free length
diameter
If damaged or
1.96 N 1.57 N
21.9 X 5.0 15.8 — deformed,
{0.2 kg} {0.16 kg}
replace spring.
15.7 N 12.6 N
{1.6 kg} {1.28 kg}
2.26 N 1.81 N
{0.23 kg} {0.18}
10-102 PC78US-6
(10)
(3/4)
10-104 PC78US-6
(10)
1. Logic valve
4. Check valve (P2)
10. Spool (Boom)
14. Spool (Arm)
19. Spool (Bucket)
26. Pressure compensation valve R (Attachment)
27. Pressure compensation valve F (Attachment)

Unit: mm

Free length x
Outside Free length
diameter
If damaged or
2.26 N 1.81 N
13.0 X 6.5 9 — deformed,
{0.23 kg} {0.18}
replace spring.
29 16.6 X 13.0 13 —
spring {1.14 kg} {0.91 kg}
30 13.0 X 8.8 7.7 —
PC78US-6 10-105
(10)
(4/4)
10-106 PC78US-6
(10)

2. Safety valve
5. LS bleed valve
9. Logic valve
Unit: mm

Free length x
Outside Free length
diameter
deformed,
27.2 X 6.9 22 —
{0.4 kg} {0.32 kg}
5.5 N 4.4 N
{0.56 kg} {0.45 kg}
PC78US-6 10-107
(10)
3. PC78UU-6 without service valve

(1) Outside view
A1: To blade cylinder head

A2: To swing motor
A3: To left travel motor
A4: To right travel motor
A5: To offset cylinder head
A6: To boom cylinder bottom
A7: To arm cylinder head
A8: To bucket cylinder head
B1: To blade cylinder bottom
B2: To swing motor
B3: To left travel motor
B4: To right travel motor
B5: To offset cylinder bottom
B6: To boom cylinder head
B7: To arm cylinder bottom
B8: To bucket cylinder bottom
BP: From boom RAISE PPC valve
LS: To pump LS valve (LS pressure input)
P1: From main pump
P2: From main pump
P3: From gear pump
PP: To pump LS valve (Pump pressure input)
PT: To travel pressure switch
TB: To tank
TC: To oil cooler
TS: To tank
PA1: From blade raise PPC valve
PA2: From swing right PPC valve
PA3: From left travel reverse PPC valve
PA4: From right travel reverse PPC valve
PA5: From offset right PPC valve
PA6: From boom raise PPC valve
PA7: From arm out PPC valve
PA8: From bucket dump PPC valve
PB1: From blade lower PPC valve
PB2: From swing left PPC valve
PB3: From left travel forward PPC valve
PB4: From right travel forward PPC valve
PB5: From offset left PPC valve
PB6: From boom lower PPC valve
PB7: From arm in PPC valve
PB8: From bucket curl PPC valve
TSW: To swing motor
10-108 PC78US-6
(10)
(PC78UU-6 without service valve)
PC78US-6 10-109
(10)
(2) Sectional view

(1/4)
10-110 PC78US-6
(10)
1. Safety-suction valve (Blade head) 30. LS pressure pickup plug (LS1)

2. Suction valve (Left travel) 31. Pressure compensation valve F (Left travel)
3. Suction valve (Right travel) 32. Pressure compensation valve F (Right travel)
4. Suction valve (Offset head) 33. Pressure compensation valve F (Offset)
5. Main relief valve 34. Pressure compensation valve F (Boom)
6. Suction valve (Boom bottom) 35. Pressure compensation valve F (Arm)
7. Suction valve (Arm head) 36. Pressure compensation valve F (Bucket)
8. Suction valve (Bucket head) 37. Pump pressure pickup plug (P2)
9. Safety valve 38. LS pressure pickup plug (LS3)
10. Suction valve (Bucket bottom) 39. Pressure compensation valve R (Bucket)
11. Suction valve (Arm bottom) 40. Pressure compensation valve R (Arm)
12. Suction valve (Boom head) 41. Pressure compensation valve R (Boom)
16. Suction valve (Blade bottom) 45. Pressure compensation valve R (Offset)
17. Gear pump relief valve 46. Pressure compensation valve R (Right travel)
18. Spool (Boom raise merge) 47. Pressure compensation valve R (Left travel)
19. Spool (Blade) 48. Check valve (Blade)
20. Spool (Swing) 49. Check valve (Swing)
21. Spool (Left travel) 50. LS bleed valve
22. Spool (Right travel) 51. Travel junction valve, LS bleed valve
23. Spool (Offset) 52. Check valve (Bucket)
24. Unload valve (P1) 53. Check valve (Arm)
25. Unload valve (P2) 54. Check valve (Boom bottom)
26. Spool (Boom)
27. Spool (Arm) F: Flow control valve
28. Spool (Bucket) R: Pressure reducing valve
PC78US-6 10-111
(10)
Unit: mm

Free length x
Cooler bypass Outside Free length
55 length load load
73.5 N 58.8 N
34.5 X 17.7 25 –
{7.5 kg} {6.0 kg}
56 29.0 X 18.3 27.5 –
(Blade, swing) {9.1 kg} {7.28 kg}
57 29.0 X 17.5 28.5 –
(Travel, offset) {2.3 kg} {1.84 kg}
58 41.1 X 19.3 40.5 –
54.9 N 43.9 N
59 Spool return spring (Arm out) 42.3 X 19.2 40.5 –
{5.6 kg} {4.48 kg}
129 N 103 N
60 Unload valve spring 40.9 X 15.1 33.5 –
{13.2 kg} {10.6 kg}
Boom RAISE merge valve 11.2 N 8.96 N
61 16.6 X 13.0 13 – If damaged or
spring {1.14 kg} {0.91 kg}
deformed,
Pump merge-divider valve 49.0 N 39.2 N replace spring.
62 33.2 X 14.2 22.5 –
63 30.9 X 5.2 20 –
spring {2.82 kg} {2.26 kg}
64 28.0 X 14.4 14.5 –
65 33.4 X 14.4 21.5 –
66 20.0 X 8.4 12 –
2.26 N 1.81 N
67 Check valve spring 13.0 X 6.5 9 –
{0.23 kg} {0.18}
3.92 N 3.14 N
68 Check valve spring 27.2 X 6.9 22 –
{0.4 kg} {0.32 kg}
3.92 N 3.14 N
69 Check valve spring 12.3 X 11.4 10.5 –
{0.4 kg} {0.32 kg}
1.96 N 1.57 N
70 Check valve spring 21.9 X 5.0 15.8 –
{0.2 kg} {0.16 kg}
10-112 PC78US-6
(10)
(2/4)
10-114 PC78US-6
(10)
1. Spool (Boom raise merge)

3. Safety-suction valve (Blade head)
4. Suction valve (Blade bottom)
5. Spool (Blade)
6. Check valve (Blade)
7. Spool (Swing)
8. Check valve (Swing)
13. LS bleed valve
21. Suction valve (Offset head)
22. Spool (Offset)
23. Pressure compensation valve R (Offset)
24. Pressure compensation valve F (Offset)

Unit: mm

Free length x
Outside Free length
diameter
deformed,
21.9 X 5.0 15.8 —
{0.2 kg} {0.16 kg}
15.7 N 12.6 N
{1.6 kg} {1.28 kg}
PC78US-6 10-115
(10)
(3/4)
10-116 PC78US-6
(10)

2. Check valve (P1)
5. Logic valve
17. Spool (Boom)
21. Spool (Arm)
26. Spool (Bucket)

Unit: mm

Free length x
Outside Free length
diameter
If damaged or
2.26 N 1.81 N
13.0 X 6.5 9 — deformed,
{0.23 kg} {0.18}
replace spring.
31 16.6 X 13.0 13 —
spring {1.14 kg} {0.91 kg}
32 13.0 X 8.8 7.7 —
PC78US-6 10-117
(10)
(4/4)
10-118 PC78US-6
(10)
1. Safety valve
5. LS bleed valve
9. Logic valve

Unit: mm

Free length x
Outside Free length
diameter
deformed,
27.2 X 6.9 22 —
{0.4 kg} {0.32 kg}
5.5 N 4.4 N
{0.56 kg} {0.45 kg}
PC78US-6 10-119
(10)
MAINTENANCE STANDARD CLSS
CLSS
OUTLINE OF CLSS
Features Structure
CLSS stands for Closed center Load Sensing Sys- • The CLSS consists of a variable capacity single
tem, and has the following featues. piston pump, control valve, and actuators.
• Fine control not influenced by load • The pump body consists of the main pump, PC
• Control enabling digging even with fine control valve and LS valve.
• Ease of compound operation ensured by flow
divider function using area of opening of spoll
during compund operations
• Energy saving using variable pump control
10-120 PC78US-6
(10)
BASIC PRINCIPLE
1. Control of pump swash plate angle
• The pump swash plate angle (pump discharge
amount) is controlled so that LS differential pres-
sure PLS (the difference between pump (dis-
charge) pressure PP and control valve outlet port
LS pressure PLS) load pressure of actuator) is
constant.
(LS pressure PLS=Pump discharge pressure
PP–LS pressure PLS)
• If LS differential pressure PLS becomes lower

than the set pressure of the LS valve (when the
actuator load pressure is high), the pump swash
plate moves towards the maximum position; if
the set pressure becomes higher than the set
pressure of the LS valve (when the actuator load
pressure is low), the pump swash plate moves
towards the minimum position.
a For details of the operation, see HYDRAULIC
PUMP.
PC78US-6 10-121
(10)
2. Pressure compensation control between the upstream (inlet port) and down-
• A pressure compensation valve is installed to the stream (outlet port) the same, regardless of the
inlet port side of the control valve spool to bal- size of the load (pressure). In this way, the flow
ance the load. of oil from the pump is divided (compensated) in
When to actuators are operated together, this proportion to the area of openings S1 and S2 of
valve acts to make pressure difference P each valve when it is operated.
10-122 PC78US-6
(10)
OPERATION FOR EACH FUNCTION AND VALVE

Hydraulic circuit diagram and name of valves
(PC78US-6 Blade-less, 1 service valve)
10-124 PC78US-6
(10)

Set pressure: LS pressure + 2.45 MPa
{25 kg/cm2}
{25 kg/cm2}
Set pressure: 26.5 MPa {270 kg/cm2}
4. Lift check valve
6. Suction valve
7. Safety valve
8. Pressure compensation valve
9. LS bypass plug (P1)
11. LS selector valve
12. LS bleed valve
14. Logic valve
PC78US-6 10-125
(10)
10-126 PC78US-6
(10)

{25 kg/cm2}
{25 kg/cm2}
6. Suction valve
7. Safety-suction valve
8. Safety valve
12. Boom raise merge valve
13. LS bleed valve
15. Logic valve
PC78US-6 10-127
(10)
(PC78US-6 without service valve)
10-128 PC78US-6
(10)

{25 kg/cm2}
{25 kg/cm2}
6. Suction valve
7. Safety-suction valve
8. Safety valve
12. Boom raise merge valve
13. LS bleed valve
15. Logic valve
PC78US-6 10-129
(10)
Unload valve
1. When control valve is at HOLD
Function • When the control valve is at HOLD, LS pres-

• When the control valve is at HOLD, pump dis- sures PLS1 and PLS2 are not generated, so
charge amount Q discharged by the minimum only pump discharge pressures PP1 and PP2
swash plate angle is released to the tank circuit. act, and PP1 and PP2 are set by only the load of
At this time, pump discharge pressure PP1/PP2 spring (2).
is set at 2.45 MPa {25.0 kg/cm2} by spring (2) in • As pump discharge pressure PP1/PP2 rises and
the valve. (LS pressure PLS1/PLS2: 0 MPa {0 reaches the load of spring (2) (2.45 MPa {25.0
kg/cm2}) kg/cm2}), spool (1) is moved to the right. Pump
• Since the pump merge-divider valve is at the discharge pressures PP1 and PP2 are con-
merge position, pump discharge pressures PP1 nected to tank circuit T through the cut of spool
and PP2 are merged. LS pressures PLS1, (1)
PLS2, and PLS3 are also merged. • As a result, pump discharge pressure PP1/PP2
is set to 2.45 MPa {25.0 kg/cm2}.
Operation
• Pump discharge pressures PP1 and PP2 are
acting on the left end of unload spool (1) and LS
pressures PLS1 and PLS2 are acting on the
right end. (PP1 = PP2, PLS1 = PLS2)
10-130 PC78US-6
(10)
2. During fine control of work equipment valve

Work equipment valve: Swing (PC78US-6 with-
out blade), boom, arm, bucket, or attachment.
Function Operation
• During fine control of the work equipment valve, • When fine control is carried out on the work
when the demand flow for the actuator is within equipment valve, LS pressures PLS1 and PLS2
the amount discharged by the minimum swash are generated and act on the right end of spool
plate angle of the pump, pump discharge pres- (1) (PP1 = PP2, PLS1 = PLS2). When this hap-
sure PP1/PP2 is set to LS pressure PLS1/PLS2 pens, the area of the opening of the work equip-
+ 2.45 MPa {25.0 kg/cm2}. When the difference ment valve spool is small, so LS pressures PLS1
between pump discharge pressure PP1/PP2 and and PLS2 are very different from pump dis-
LS pressure PLS1/PLS2 reaches the load of charge pressures PP1 and PP2.
spring (2) (2.45 MPa {25.0 kg/cm 2 }), unload • When the difference between pump discharge
spool (1) opens, so LS differential pressure pressure PP1/PP2 and LS pressure PLS1/PLS2
PLS becomes 2.45 MPa {25 kg/cm2}. reaches the load of spring (2) (2.45 MPa {25.0
• Since the pump merge-divider valve is at the kg/cm2}), spool (1) moves to the right, and pump
merge position, pump discharge pressures PP1 discharge pressures PP1 and PP2 are con-
and PP2 are merged. LS pressures PLS1, nected to tank circuit T.
PLS2, and PLS3 are also merged. • In other words, pump discharge pressure PP1/
PP2 is set to the spring force (2.45 MPa {25.0
kg/cm2}) + LS pressure PLS1/PLS2, and LS dif-
ferential pressure PLS becomes 2.45 MPa
{25.0 kg/cm2}.
PC78US-6 10-131
(10)
3. When work equipment valve is operated

out blade), boom, arm, bucket, or attachment
Function • For this reason, the difference between pump

• When any work equipment valve is operated if discharge pressure PP1/PP2 and LS pressure
the demand flow for the actuator becomes PLS1/PLS2 does not reach the load of spring (2)
greater than the pump discharge from the mini- (2.45 MPa {25.0 kg/cm2}), so spool (1) is pushed
mum swash plate angle, the oil flow to tank cir- to the left by spring (2).
cuit T is cut off, and all pump discharge amount • As a result, pump discharge pressures PP1 and
Q flows to the actuator circuit. PP2 and tank circuit T are shut off, and all pump
• Since the pump merge-divider valve is at the discharge amount Q flows to the actuator circuit.
merge position, pump discharge pressures PP1
and PP2 are merged. LS pressures PLS1,
PLS2, and PLS3 are also merged.
Operation
• When any work equipment valve is operated for
a long stroke, LS pressures PLS1 and PLS2 are
generated and act on the right end of unload
spool (1) (PP1 = PP2, PLS1 = PLS2). When this
happens, the area of the opening of the work
equipment valve spool is large, so LS pressures
PLS1 and PLS2 are not so different from pump
discharge pressures PP1 and PP2.
10-132 PC78US-6
(10)
4. During fine control of both travel valves
Function Operation
• During fine control of both travel valves, when • When fine control is carried out on both travel
the demand flow is below the maximum pump valves, LS pressures PLS1 and PLS2 are gener-
discharge amount, pump discharge pressure ated and act on the right end of spool (1) (PP1,
PP1/PP2 is set to LS pressure PLS1/PLS2 + PP2, PLS1, and PLS2 are separated).
2.45 MPa {25.0 kg/cm2}. • When this happens, the area of the opening of
• When the difference between pump discharge both travel valve spools is small, so LS pres-
pressure PP1/PP2 and LS pressure PLS1/PLS2 sures PLS1 and PLS2 are very different from
reaches the load of spring (2) (2.45 MPa {25.0 pump discharge pressures PP1 and PP2.
kg/cm2}), unload spool (1) opens, so excessive • When the difference between pump discharge
oil (maximum pump discharge mount – demand pressure PP1/PP2 and LS pressure PLS1/PLS2
flow) flows into the tank circuit. reaches the load of spring (2) (2.45 MPa {25.0
• Since the pump merge-divider valve is at the kg/cm2}), spool (1) moves to the right, and pump
separate position, pump discharge pressures discharge pressures PP1 and PP2 are con-
PP1 and PP2 are separated. LS pressures PLS1 nected to tank circuit T and the excessive oil
and PLS2 are also separated. (maximum pump discharge mount – demand
• The swash plate angle of the pump becomes flow) flows.
maximum, so the pump discharge amount • In other words, the excessive oil (maximum
becomes maximum. (For details, see the sec- pump discharge mount – demand flow) above
tions on the pump merge-divider valve and logic the strokes of both travel valves flows into tank
valve.) circuit T.
PC78US-6 10-133
(10)
5. When both travel valves are operated
Function • When this happens, the area of the openings of

• During operation of both travel valves, when the both travel valve spools is large, so LS pressures
demand flow becomes maximum, the oil flow to PLS1 and PLS2 are not so different from pump
tank circuit T is cut off, and all pump discharge discharge pressures PP1 and PP2.
amount Q flows to both travel circuits. • For this reason, the difference between pump
• Since the pump merge-divider valve is at the discharge pressure PP1/PP2 and LS pressure
separate position, pump discharge pressures PLS1/PLS2 does not reach the load of spring (2)
PP1 and PP2 are separated. LS pressures PLS1 (2.45 MPa {25.0 kg/cm2}), so spool (1) is pushed
and PLS2 are also separated. to the left by spring (2).
• The swash plate angle of the pump becomes • As a result, pump discharge pressures PP1 and
maximum, so the pump discharge amount PP2 and tank circuit T are shut off, and all pump
becomes maximum. (For details, see the sec- discharge amount Q flows to the actuator circuit.
tions on the pump merge-divider valve and logic
valve.)
Operation
• When both travel valves are operated to the
stroke ends, LS pressures PLS1 and PLS2 are
generated and act on the right end of unload
spool (1) (PP1, PP2, PLS1, and PLS2 are sepa-
rated).
10-134 PC78US-6
(10)
6. When either travel valve is operated
Function • When this happens, the area of the openings of

• The demand flow decided by the valve stroke is both travel valve spools is large, so LS pressures
sent to the travel circuit on the operated travel PLS1 is not so different from pump discharge
valve side and the all pump discharge amount is pressures PP1.
sent to the tank circuit on the non-operated travel • For this reason, the difference between pump
valve side. discharge pressure PP1 and LS pressure PLS1
• Since the pump merge-divider valve is at the does not reach the load of spring (2) (2.45 MPa
separate position, pump discharge pressures {25.0 kg/cm2}), so spool (1) is pushed to the left
PP1 and PP2 are separated. LS pressures by spring (2).
PLS1 and PLS2 are also separated. • As a result, pump discharge pressures PP1 and
• The swash plate angle of the pump becomes tank circuit T are shut off, and all pump dis-
maximum, so the pump discharge amount charge amount QP1 on the P1 side flows to the
becomes maximum. (For details, see the sec- left travel circuit.
tions on the pump merge-divider valve and logic • Since the right travel valve is at HOLD, LS pres-
valve.) sure PLS2 is not generated, so only pump dis-
charge pressure PP2 acts.
Operation • When pump discharge pressure PP2 reaches
When left travel valve is operated to stroke end and the load of spring (4) (2.45 MPa {25.0 kg cm2}),
right one is at HOLD. spool (3) moves to the right, and all pump dis-
• When the left travel valve is operated to the charge amount QP2 on the P2 side flows into
stroke end, LS pressure PLS1 is generated and tank circuit T.
acts on the right end of unload spool (1).
PC78US-6 10-135
(10)
Pump merge-divider valve and logic valve

1. When control valve is at HOLD
Function
• Pump merge-divider valve spool (3) merges
pump discharge pressures PP1 and PP2 and LS
pressures PLS1, PLS2, and PLS3 respectively.
Operation
• When the control valve is at HOLD, changeover
pressure is not generated on logic spool (1), so
spring (2) pushes spool (1) to the left.
• Since both travel valves are at HOLD, changeover
pressure is not generated on the pump merge-
divider spool.
• When the control valve is at HOLD, changeover
pressure is not generated on the pump merge-
divider spool, so spring (4) pushes spool (3) to
the right.
• Pump discharge pressures PP1 and PP2 and LS
pressures PLS1, PLS2, and PLS3 are merged
respectively (PP1 = PP2, PLS1 = PLS2 = PLS3).
10-136 PC78US-6
(10)
2. When work equipment valve is operated

(including compound operation of work
equipment + travel).
out blade), boom, arm, bucket, or attachment.
Function • When the work equipment valve is operated,

• Pump merge-divider valve spool (3) merges pump changeover pressure for spool (3) is not gener-
discharge pressures PP1 and PP2 and LS pres- ated, so spring (4) pushes spool (3) to the right.
sures PLS1, PLS2, and PLS3 respectively. • Pump discharge pressures PP1 and PP2 are
• As the LS pressure, PLS1, PLS2, and PLS3 are merged. LS pressures PLS1, PLS2, and PLS3
output. are also merged (PP1 = PP2, PLS1 = PLS2 =
PLS3).
Operation
• When any work equipment valve is operated, the
work equipment PPC pressure or the swing hold-
ing brake release pressure is introduced in the
left chamber of logic spool (1) to change over
spool (1).
• When the load of spring (2) reaches 0.6 MPa {6
kg/cm2}, spool (1) moves to the right.
• As a result, the right chamber of spool (3) is con-
nected to tank circuit T and changeover pressure
for spool (3) is not generated.
PC78US-6 10-137
(10)
3. When either or both travel valves are oper-

ated
Function • Furthermore, PP1 and PLS1 are separated for

• Pump merge-divider valve spool (3) separates the left travel circuit and PP2 and PLS2 are sep-
pump discharge pressures PP1 and PP2 and LS arated for the right travel circuit.
pressures PLS1, PLS2, and PLS3 respectively. • The higher pressure of pump discharge pres-
• As the LS pressure, higher pressure of PP1 and sures PP1 and PP2 is output as the LS pressure
PP2 is output. and the swash plate angle of the pump becomes
maximum, so the pump discharge amount
Operation becomes maximum.
• Since the all work equipment valves are at
HOLD, changeover pressure for logic spool (1) is
not generated, spring (2) pushes spool (1) to the
left.
• When both travel valves are operated, travel
PPC pressure is introduced as changeover pres-
sure for spool (3) through spool (1) into the right
chamber of spool (3).
• When the load of spring (4) reaches 0.49 MPa {5
kg/cm2}, spool (3) is pushed to the left.
• As a result, pump discharge pressures PP1 and
PP2 and LS pressures PLS1 and PLS2 are sep-
arated respectively.
10-138 PC78US-6
(10)
Introduction of LS pressure
1. Work equipment valve: Swing (PC78US-6
without blade), boom, arm, bucket, or attach-
ment
Function • When this happens, LS circuit PLS is connected

• The LS pressure is the actuator load pressure at to tank circuit T from LS bypass plug (4) (See the
the outlet port end of the control valve. section on the LS bypass plug).
• Actually, pump discharge pressure PP is reduced • The areas at both ends of reducing valve (3) are
by reducing valve (3) of the pressure compensa- the same (SA = SLS), and actuator circuit pres-
tion valve to the same pressure as actuator circuit sure PA acts on the SA end. The reduced pump
pressure A and sent to LS circuit PLS. discharge pressure PP acts on SLS at the other
• In the travel valve, actuator circuit pressure A is end.
directly introduced to LS circuit PLS. • As a result, reducing valve (3) is balanced at a
position where actuator circuit pressure PA and
Operation the pressure of spring chamber PLSS are the
• When spool (1) is operated, pump discharge same. Pump discharge pressure PP reduced at
pressure PP flows from flow control valve (2) notch (c) becomes actuator pressure A and is
through notch (a) in the spool and bridge pas- introduced into LS circuit PLS.
sage (b) to actuator circuit A.
• At the same time, reducing valve (3) also moves
to the right, so pump discharge pressure PP is
reduced by the pressure loss at notch (c). It goes
to LS circuit PLS, and then goes to spring cham-
ber PLSS.
PC78US-6 10-139
(10)
2. Travel valve
Operation
• When spool (1) is operated, pump discharge
pressure PP flows from flow control valve (2)
through notch (a) in the spool and bridge pas-
sage (b) to actuator circuit A.
• At the same time, reducing valve (3) is moved to
the right by actuator circuit pressure PA, and
notch (c) and notch (d) are interconnected
respectively with travel junction circuit (e) and LS
circuit PLS.
• As a result, actuator circuit pressure PA (= A) is
introduced from notch (c) through the internal
check valve and notch (d) into LS circuit PLS.
a The travel circuit is different from the work equip-

ment circuit: actuator circuit pressure PA is
directly introduced into LS circuit PLS.
10-140 PC78US-6
(10)
LS bypass plug
When work equipment valve is operated
When both travel valves are operated
Function PLS1, PLS2, and PLS3 flows from tip filter

• The LS bypass plug releases the residual pres- (a) of LS bypass plug (2) through orifice (b)
sure of LS pressure PLS. to tank circuit T.
• This lowers the rising speed of LS pressure PLS. 2. When either or both travel valves are operated
In addition, the discarded throttled flow causes a • Since pump merge-divider spool (1) is at the
pressure loss in the throttled flow in the reducing separate position, LS circuits PLS1, PLS2,
valve, and that lowers the effective LS differential and PLS3 are separated.
pressure to improve the stability. • The hydraulic oil PLS1 flows from tip filter (a)
of LS bypass plug (3) on the P1 side through
Operation orifice (b) to tank circuit T.
1. When work equipment valve is operated (includ- • The hydraulic oil PLS2 flows from tip filter (a)
ing compound operation of work equipment + of LS bypass plug (2) on the P2 side through
travel) orifice (b) to tank circuit T.
• Since pump merge-divider spool (1) is at the
merge position, the hydraulic oil in LS circuits
PC78US-6 10-141
(10)
LS selector valve (only PC78US-6 without blade)

Function
• When the machine swings and the boom is raised
simultaneously, this valve prevents the high-pres-
sure swing LS pressure from entering LS circuit
PLS and secures sufficient pump discharge
amount to keep the boom raising speed.
Operation
1. During normal operation
• When the boom is not raised, the pilot pressure

is not applied to pilot port BP.
• Under this condition, pump discharge pressure
PP is introduced through the internal passage of
spool (1) into reducing valve (3) of the swing
valve. When the swing lever is operated, LS
pressure PLS is generated according to the load
pressure and sent to the pump LS valve.
10-142 PC78US-6
(10)
2. When machine swings and boom is raised

simultaneously.
• When the machine swings and boom is raised

simultaneously, the signal pressure of the boom
RAISE PPC circuit is applied to pilot port BP.
• When pilot pressure BP acts on spool (1) and
increases above the force of spring (2), spool is
pushed to the right and the internal passage is
closed, then pump discharge pressure PP does
not flow into reducing valve (3) of the swing
valve.
• As a result, swing LS pressure PLS is not gener-
ated and only the boom RAISE LS pressure is
introduced in the pump LS valve to control the
pump discharge amount.
• The level of pilot pressure BP is decided by the
stroke of the control lever (Boom RAISE)
PC78US-6 10-143
(10)
Boom raise merge valve (PC78US-6 with blade, PC78UU-6)

During normal operation
When machine swings and boom is raised simultaneously
Function 2. When machine swings and boom is raised simul-

• When the machine swings and the boom is taneously
raised simultaneously, this valve merges dis- • When the machine swings and boom is raised
charge amount of the gear pump into that of simultaneously, the signal pressure of the
main pump to heighten the boom raising speed. boom RAISE PPC circuit is applied to pilot
port BP.
Operation • When pilot pressure BP acts on spool (1)
1. During normal operation and increases above the force of spring (2),
• When the boom is not raised, the pilot pres- spool is pushed to the right. Then, check
sure is not applied to pilot port BP. valve (3) in spool (1) is pushed open and oil
• Under this condition, gear pump circuit P3 in gear pump circuit P3 is merged into that in
and main pump circuit PP are shut off by main pump circuit PP to heighten the boom
spool (1), so oil in gear circuit P3 is not raising speed.
merged into that of main pump circuit PP.
10-144 PC78US-6
(10)
Area ratio of pressure compensation valve
Function Area ratio (S1:S2) and compensation character-

• The pressure compensation valve determines istics
the compensation characteristics by carrying out • When ratio is 1.00: [Pump discharge pressure
fine adjustment of the area r atio (S2/S1) PP – spool notch upstream
between (left) area S1 of flow control valve (2) pressure PPB] = [LS circuit
and (right) area S2 of reducing valve (1) to match pressure PLS – actuator cir-
the characteristics of each actuator. cuit pressure PA (= A)] and
oil flow is divided in propor-
S1: Area of flow control valve (2) – area of piston (3) tion to area of opening of
S2: Area of reducing valve (1) – area of piston (3) spool.
• When ratio is more than 1.00:PP – PPB > PLS –
PA ( = A) and oil fl ow i s
divided in a proportion less
tha n ar ea of ope ning of
spool.
• When ratio is less than 1.00:PP – PPB < PLS –
PA ( = A) and oil fl ow i s
divided in a proportion more
tha n ar ea of ope ning of
spool.
PC78US-6 10-145
(10)
Pressure compensation valve
Function • Flow control valve (2) and reducing valve (1) are
• During compound operations, if the load pres- balanced in a position where the difference
sure on either actuator becomes lower than the between PLS and PA acting on both ends of
other actuator and the oil flow is about to reducing valve (1) and the pressure loss made
increase, compensation is made. [When this between PP and PPA on the sides of flow control
happens, the other actuator being used for com- valve (2) will be the same.
pound operation (right side) is at a high load than • In this way, the pressure difference between
the actuator on this side (left side).] upstream pressure PPA and downstream pres-
sure PA of both spools used during compound
Operation operations is the same, so the pump flow is
• When the load pressure on the other actuator divided in proportion to the area of opening of
(right side) becomes higher during compound notch (a) of each spool.
operations, the oil flow in actuator circuit A on
this side (left side) starts increasing.
• When this happens, the LS pressure PLS on the
other actuator acts on spring chamber PLSS,
and reducing valve (1) and flow control valve (2)
are pushed to the left.
• Flow control valve (2) throttles the area of open-
ing between pump circuit PP and spool upstream
PPA to cause a pressure loss between PP and
PPA.
10-146 PC78US-6
(10)
Boom hydraulic drift prevention valve

Function
• This valve prevents the oil in the boom cylinder
bottom from leaking through spool (1) to cause
hydraulic drift of the boom while the boom control
lever is not operated.
1. When boom is raised
Operation
• When the boom is "raised", the main pressure
from the control valve pushes up puppet (2). As
a result, the hydraulic oil from the control valve
flows through the valve into the boom cylinder
bottom.
PC78US-6 10-147
(10)
2. When boom is held
• When the boom control lever is returned to the

neutral position after the boom is raised, the
holding pressure on the boom cylinder bottom
side is closed by puppet (2) and the hydraulic oil
that flowed through orifices (a1) and (a2) is
closed by pilot spool (3). Accordingly, the boom
is held.
10-148 PC78US-6
(10)
3. When boom is lowered
• When the boom is lowered, pilot pressure P1

from the PPC valve pushes pilot spool (3) and
the hydraulic oil in chamber (b) in the puppet is
drained.
• The pressure in port (Ab) is heightened by the
hydraulic oil from the boom cylinder bottom, but
the pressure in chamber (b) is lowered by ori-
fices (a1) and (a2).
• When the pressure in chamber b lowers below
that in port (Ab), puppet (2) opens and the
hydraulic oil from port (Ab) flows through port
(Aa) into the control valve.
PC78US-6 10-149
(10)
Boom regeneration circuit

1. When boom is lowered by its weight.
Function • When this happens, a part of the return oil on the

• While the boom is being lowered by its weight, if bottom side flows through regeneration pas-
bottom pressure A of cylinder (1) is higher than sages (a) of bottom spool (2), pushes check
head pressure B, this circuit sends the return oil valve (3) open, and flows into the head side.
on the bottom side to the head side to increase • As a result, the boom lowering speed is height-
the cylinder speed by that amount. ened.
Operation
• While the boom is being lowered by its weight,
pressure A on the bottom side of boom cylinder
(1) is higher than pressure B on the head side.
10-150 PC78US-6
(10)
2. When boom is lowered under a load.
Function
• While the boom is being lowered under a load, if
head pressure B of cylinder (1) is higher than
bottom pressure A, check valve (3) is closed to
shut off the head side and bottom side from each
other.
Operation
• While the boom is being lowered under a load,
pressure B on the head side of boom cylinder (1)
is higher than pressure A on the bottom side.
• When this happens, check valve (3) is closed by
pressure B on the head side and spring (4) to
shut off the head side and bottom side from each
other.
PC78US-6 10-151
(10)
Travel junction valve

(L.H., R.H. travel junction circuit)
1. When traveling in a straight line
10-152 PC78US-6
(10)
2. When steered during travel
PC78US-6 10-153
(10)
Function
• To compensate for any difference in the oil flow
in the left and right travel circuits while machine
travels in a straight line, the junction circuit
opens when the left and right travel spools are
operated.
• In this way, the flow rates of oil to the left and
right travel motors are almost the same when the
machine travels in a straight line, so the machine
deviates less.
• When the machine is steered, the junction circuit
opens. Since opening (b) of travel junction valve
spool (3) is small, however, the junction circuit
does not affect the steering performance.
Operation
1. When traveling in a straight line
• Since only both travel valves are operated
and any work equipment valve is not oper-
ated, pump discharge circuits PP1 and PP2
and LS circuits PLS1 and PLS2 are sepa-
rated by the pump merge-divider spool.
(See the section on the LS bypass plug).
• When both travel spools (1) are operated,
the oil from the pump flows from pump dis-
charge circuits PP1 and PP2 through actua-
tor circuit PB to B.
• When the machine travels in straight line,
both reducing valves (2) are pushed to the
right and notch (a) and travel junction circuit
are opened.
• The right end of travel junction spool (3) is
the work equipment PPC pressure circuit.
Since the work equipment valve is not oper-
ated at this time, however, any pressure is
not generated.
• In this way, both travel actuator circuits are
interconnected by the travel junction circuit.
If any difference occurs in the flow of oil to
both travel motors, the difference is compen-
sated to reduce travel deviation.
2. When steered during travel
• Since only both travel valves are operated
and any work equipment valve is not oper-
ated, pump discharge circuits PP1 and PP2
and LS circuits PLS1 and PLS2 are sepa-
rated by the pump merge-divider spool.
(See the section on the LS bypass plug).
• The machine is steered by supplying the
demand flow to the actuator circuit according
to the strokes of both travel spools. (See the
section on the unload valve.)
• While the machine is traveling in a straight
line, if the right travel spool (right 1) is
returned to the neutral position and the
machine is steered, a difference (left B >
right B) is made between the load pressures
in both travel actuator circuits PB.
10-154 PC78US-6
(10)
Travel LS bleed circuit and travel junction valve

PC78US-6 10-155
(10)
2. When travel actuator and another actuator

are operated
10-156 PC78US-6
(10)
Function • As a result, reducing valve (2) moves to the

• When the travel actuator and another actuator left and LS pressure PLS flows through
are operated at the same time, the amount of oil check valves (3) and (4) and notch (a) of
discarded through the throttle in LS circuit PLS reducing valve (2) to travel circuit PB.
increases and the pressure compensation preci- • For this reason, LS circuit pressure PLS,
sion of the travel circuit is lowered to reduce the which is the same pressure as boom circuit
drop of the travel speed. pressure A, flows to travel circuit B to reduce
• When the travel actuator or any other actuator is the pressure.
operated singly, the LS bleed circuit is closed.
• Travel junction valve spool (5) is set to open (b)
(small) or open (c) (large) by the boom PPC
pressure so that the difference between the flow
rates in both travel circuits can be corrected eas-
ily.
Operation
• When boom spool (1) is operated, LS circuit
PLS becomes the same pressure as boom
circuit pressure A.
• Since the work equipment valve is operated,
pump discharge pressures PP1 and PP2 are
merged by the pump merge-divider valve
spool. LS pressures PLS1, PLS2, and PLS3
are also merged. (See the sections on the
pump merge-divider valve and logic valve.)
• At the same time, LS pressure PLS also
goes to spring chamber PLSS of reducing
valve (2) of the travel valve.
• Since the travel valve spool is not operated,
notch (a) of reducing valve (2) is closed, and
check valves (3) and (4) of the bleed circuit
are also closed.
• As a result, when the boom is operated sin-
gly, the travel LS bypass circuit is closed.
2. When travel actuator and another actuator are
operated
• When boom spool (1) is operated, LS circuit
PLS becomes the same pressure as boom
circuit pressure A.
• Since the work equipment valve is operated,
pump discharge pressures PP1 and PP2 are
merged by the pump merge-divider valve
spool. LS pressures PLS1, PLS2, and PLS3
are also merged. (See the sections on the
pump merge-divider valve and logic valve.)
• As for the actuator circuit pressure, the boom
RAISE pressure is normally higher than the
travel pressure (A > B), so the pressure in
spring chamber PLSS inside reducing valve
(2) of the travel valve is higher than travel cir-
cuit pressure PB.
PC78US-6 10-157
(10)
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM

PC78US-6 Serial No.: 4001 – 6500 (Blade-less specification)........... 90- 3
PC78US-6 Serial No.: 6501 and up (Blade-less specification).......... 90-3-2
PC78US-6 (Additional attachment circuit)........................................... 90- 5
PC78US-6 Serial No.: 4001 – 6500 (Blade specification) .................. 90- 7
PC78US-6 Serial No.: 6501 and up (Blade specification) ................. 90-7-2
PC78US-6 Serial No.: 4809 – 6500 (Norway & EU specification) ..... 90-7-4
PC78US-6 Serial No.: 6501 and up (Norway & EU specification) ..... 90-7-6
PC78UU-6.......................................................................................... 90-7-8
ELECTRICAL CIRCUIT DIAGRAM

PC78US-6 Serial No.: 4001 – 5500 (1/2)........................................... 90- 9
PC78US-6 Serial No.: 4001 – 5500 (2/2)............................................90-11
PC78US-6 Serial No.: 5501 – 6500 (1/2)........................................... 90-13
PC78US-6 Serial No.: 5501 – 6500 (2/2)........................................... 90-15
PC78US-6 Serial No.: 6501 and up (1/2)....................................... 90-15-2
PC78US-6 Serial No.: 6501 and up (2/2)....................................... 90-15-4
PC78US-6 Serial No.: 4809 – 5500
(Norway & EU specification) (1/2) ..................................................... 90-17
PC78US-6 Serial No.: 4809 – 5500
PC78US-6 Serial No.: 5501 – 6500
PC78US-6 Serial No.: 5501 – 6500
PC78US-6 Serial No.: 6501 and up
(Norway & EU specification) (1/2) .................................................. 90-23-2
PC78US-6 Serial No.: 6501 and up
(Norway & EU specification) (2/2) .................................................. 90-23-4
PC78UU-6 Serial No.: 22832 – 23500 (1/2)....................................... 90-25
PC78UU-6 Serial No.: 22832 – 23500 (2/2)....................................... 90-27
PC78UU-6 Serial No.: 23501 and up (1/2)......................................... 90-29
PC78UU-6 Serial No.: 23501 and up (2/2)......................................... 90-31
PC78US-6 90-1
HYDRAULIC CIRCUIT DIAGRAM *1. Serial No.: 4001 – 4248 *3. Serial No.: 4001 – 5500
PC78US-6 Serial No.: 4001 – 6500 (Blade-less specification) *2. Serial No.: 4249 and up *4. Serial No.: 5501 and up
PC78US-6 90-3
(10)
PC78US-6 (Additional attachment circuit)
PC78US-6 90-5
PC78US-6 Serial No.: 6501 and up (Blade-less specification)
PC78US-6 90-3-2
(10)
PC78US-6 Serial No.: 4001 – 6500 (Blade specification) *1. Serial No.: 4001 – 4248 *3. Serial No.: 4001 – 5500
*2. Serial No.: 4249 and up *4. Serial No.: 5501 and up
PC78US-6 90-7
(10)
PC78US-6 Serial No.: 6501 and up (Blade specification)
PC78US-6 90-7-2
(10)
PC78US-6 Serial No.: 4809 – 6500 (Norway & EU specification) *1. Serial No.: 4809 – 5500
*2. Serial No.: 5501 and up
PC78US-6 90-7-4
(14)
PC78US-6 Serial No.: 6501 and up (Norway & EU specification)
PC78US-6 90-7-6
(14)
PC78UU-6 *1. Serial No.: 22832 – 23500
*2. Serial No.: 23501 and up
PC78US-6 90-7-8
(10)
PC78US-6 Serial No.: 4001 – 5500 (1/2)
PC78US-6 90-9
PC78US-6 Serial No.: 4001 – 5500 (2/2)
PC78US-6 90-11
PC78US-6 Serial No.: 5501 – 6500 (1/2)
PC78US-6 90-13
(10)
PC78US-6Serial No.: 5501 – 6500 (2/2)
PC78US-6 90-15
(10)
PC78US-6 Serial No.: 6501 and up (1/2)
PC78US-6 90-15-2
(10)
PC78US-6 Serial No.: 6501 and up (2/2)
PC78US-6 90-15-4
(10)
PC78US-6 Serial No.: 4809 – 5500 (Norway & EU specification) (1/2)
PC78US-6 90-17
(10)
PC78US-6 90-19
(10)
PC78US-6 90-21
(10)
PC78US-6 90-23
(10)
PC78US-6 Serial No.: 6501 and up (Norway & EU specification) (1/2)
PC78US-6 90-23-2
(10)
PC78US-6 Serial No.: 6501 and up (Norway & EU specification) (2/2)
PC78US-6 90-23-4
(10)
PC78UU-6 Serial No.: 22832 – 23500 (1/2)
PC78US-6 90-25
PC78UU-6 Serial No.: 22832 – 23500 (2/2)
PC78US-6 90-27
PC78UU-6 Serial No.: 23501 and up (1/2)
PC78US-6 90-29
PC78UU-6 Serial No.: 23501 and up (2/2)
PC78US-6 90-31

PC78UU-6 Nho

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STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD HYDRAULIC PUMP

P1 : Pump discharge PD2 : Pump drain (plug)

PC78US-6 (without blade) Serial No.: 4001 – 5500

P1 : Pump discharge PDA: Air bleeder

T : Drain PD2 : Drain (Plug)

PDE: EPC drain

PC78US-6 (with blade) Serial No.: 5501 – 6500

P1 : Pump discharge PD2 : Pump drain (plug)

T : Drain PAV : Pump average pressure

PC78US-6 (without blade) Serial No.: 5501 – 6500

P1 : Pump discharge PDA: Air bleeder

T : Drain PD3 : Drain

PDE: EPC drain

PC78US-6 (with blade) Serial No.: 6501 and up

P1 : Pump discharge PD2 : Pump drain (plug)

T : Drain PAV : Pump average pressure

PC78US-6 (without blade) Serial No.: 6501 and up

P1 : Pump discharge PDA: Air bleeder

T : Drain PD3 : Drain

PDE: EPC drain

Function • The oil in each cylinder of cylinder block (7) can

Operation • If center line X of rocker cam (4) is in the direc-

• If the angle between the center line X of rocker

2. Control of discharge LS valve

PC valve • At this time, ports F and G of the LS valve are

When load is light

When load is heavy

2. PC78US-6 (Without blade)

When load is heavy

PC78US-6 • Blade-less, without service valve

PC78UU-6 • Without service valve

a Since each service valve is of add-on type, it can

1. PC78US-6 blade-less and with 1 service

A1: To swing motor PT: To travel pressure switch

(PC78US-6 blade-less and with 1 service valve)

(2) Sectional view

(PC78US-6 blade-less and with 1 service valve)

Serial No.: 6501 and up

(PC78US-6 blade-less and with 1 service valve)

1. Suction valve (Left travel) 29. Pressure compensation valve F (Swing)

(PC78US-6 blade-less and with 1 service valve)

No. Item Criteria Remedy

Basic dimensions Allowable limit

(PC78US-6 blade-less and with 1 service valve)

Serial No.: 4001 – 6500

(PC78US-6 blade-less and with 1 service valve)

Serial No.: 6501 and up

(PC78US-6 blade-less and with 1 service valve)

1. Spool (LS selector)

F: Flow control valve

No. Item Criteria Remedy

Basic dimensions Allowable limit

(PC78US-6 blade-less and with 1 service valve)

(PC78US-6 blade-less and with 1 service valve)

1. Unload valve (P2)

F: Flow control valve

No. Item Criteria Remedy