ÇUKUROVA

BACKHOE LOADERS

TEST TRAINING BOOKLET

(KG.2.040eR00)
FOREWORDS
This book is prepared by our factory to give required information for testing machine
effectively by test operators wheather it fullfils (conforms) required criteria of ÇUKUROVA
brand quality standars. Final product features of produced machine and informations needed
through testing are icluded in this publish.

The tests in concept of this book, should be performed by test operators who has enough
capability and proficiency.

This book should be studied by the test operator before starting to test.

Incase of any needed on detailed test data or technical information during the test, please look
design documents of the machine or in question parts.

During the control tests of the machine, the directions and warnings sited in this book must be
considered. Be sure that, the latest information or data is taken about each step of the test
action before starting the test.

PREPARED APPROVED
Ali Rutil ÖZDEMİR Serhat ÇELİKTA Doküman No :KG.2.040e
Rev.No:00/28.01.2014
Sayfa : /

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INDEX

FOREWORDS..........................................................................................................................2
MACHINE INFORMATION..................................................................................................4
QUALITY CONTROL TEST EQUIPMENTS FOR MACHINE TEST............................7
QUALITY CONRTOL TEST SAFETY INSTRUCTIONS…………………………….…7
VEHICLE QUALITY CONTROL TESTS............................................................................9
A. Mechanical Controls….......................................................................................9
B. Pressure Controls...............................................................................................11
C. Level Controls...................................................................................................14
D. Lubrication Controls…...................................................................................17
E. Engine Speed Controls......................................................................................18
F. Functional Controls….......................................................................................19
G. Hydraulic System Controls…...........................................................................20
H. Control of Electrıcal Components.....................................................................23
I. Vısual Controls..................................................................................................23
NOMENCLATURE................................................................................................................24

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MACHINE INFORMATION

This booklet contains instructions for final tests of ÇUKUROVA brand backhoe
loaders such as 880, 883, 885, 888. Working weights and capacities may differ in different
model and different configuration machines. The information about capacities and detailed
technical features of machines should be reached by technical documents.

The main groups and main parts of bachoe loader are demonstrated below in order not
to cause missunderstanding in any expressions.

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Cabin

Tracking Group

5
Loader Group

Excavator Group

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QUALITY CONTROL TEST EQUIPMENTS FOR MACHINE TEST

• Measuring tape
• Tachometer
• Manometer (0-320 bar)
• Manometer (0-60 bar)
• Infrared thermometer
• Bomometer
• Oil impurity measuring device
• Tire pressure gauge
• Torque meter

QUALITY CONRTOL TEST SAFETY INSTRUCTIONS

• Take all precautions in test area not to cause any damage or harm anybody.
• Do not start the test before learning technical information of the vehicle and
attachments completely.
• In case of emergency keep an easy accessible functional fire extinguisher near in test
area. Make sure you know how to use it.
• Make sure seat belt was fastened before starting the test. During the test, wear helmet
absolutely.
• Never attempt any intervention under the vehicle while engine was running during the
test. In case of an intervention under the vehicle, stop the engine and anchor the
vehicle with chocks.
• Do not hit any hydraulic cylinder except 1.boom cylinder and swing cylinder to the
rod or bottom side with rapid strike during the functional and hydraulic system
controls, while engine was at full throttle and levers were pulled to the end of stroke.
Never steer the vehicle to reverse direction without release the throttle and slow down
during cruising in straight road or ramp.
• Check the engine temperature continuously during the test. If engine temperature gets
higher than desired values, stop operation and try to find source of the heat.

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• Temeperature of hydraulic tank should not exceed 80°C. If hydraulic tank temperature
increase over 80°C quickly and does not decrease, stop the test and try to find the
reason.
• Be careful about electric leakage during the test. If any smoke or smell was spotted,
stop the test immediately and try to find the source of the smoke or smell. Report all
findings to the relevant people.
• Never smoke in vehicle or around the vehicle or next to the batteries during the test.
• In case of any welding operations, disconnect the battery cables first. Make sure
connect the ground cable near to the welding area as possible as it be.
• Keep an easy accessible fire extinguisher which is known how to use, during the
welding operation.
• Disconnect the battery cables before making any repair and maintenance on electrical
system.
• Never leave the vehicle without a “OUT OF ORDER, DO NOT OPERATE” warning
sign in steering wheel while removing or unplugging any part of vehicle for
adjustments in vehicle.
• Do not wear loose clothes, ties, rings and bracelets next to the moving parts. Wear
proper outfit. Never perform the test with oily outfit or oily clothes.
• Do not put the tools, instruments and parts on the vehicle or carry them on pockets.
Put them on the work table next to you. These equipments can cause serious damages
if they drop into the moving parts of vehicle.
• Engine must not be cleaned, adjusted or oil chanced while operating. All these
processes must be done after stopping the engine.
• During the test and operating temperature, radiator water is hot and under pressure. Do
not open it before the heat temperature decreases ton the levels which could be
opened with hand.
• Never stop the engine immediately after the test while it is hot. Operate it for 4-5
minutes on idle running and then stop the engine.
• During the test, hydraulic tank is hot and under pressure on operating temperature.
Also hydraulic oil under pressure is exist in hydraulic batteries in vehicles(if
available). Do not remove any pipes, fittings or blocks…etc. in hydraulic/hydrostatic
system, without oil cool down, empty the hydraulic batteries and make all the moving
parts of vehicle stable, take down and compress slightly, for any adjustments or test.

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 • Put all the available locks and safety sheet bars(steering wheel locking sheet bars,
transmission safety lock…etc.) to their slots, if pressure is measured and tested while
vehicle stands without moving. Pull the handbrake and place chocks on wheels.
• On every start up and before operating, make sure there is no one under or around the
vehicle, in sections.
• Make sure the manometer, used for checking the tire pressure, is regulated. If
necessary, check tire pressures with another one. Tires with over pressure could cause
mortal accidents.
• Check the rim segment fitted properly. If an unfitted tire with segment is detected, do
not start to test, inform the relevant immediately.
• Never leave any oily, wet and slippery surface on vehicle where moved and walked
on. Start the test after cleaned and dried.
• Never let someone get on the vehicle for any purpose during the test.
• If there is a missing part of vehicle which is an obstacle to the test do not start the test
without getting any written permission and approval from superiors.
• Do not perform any process except these instructions if the safety conditions is not
certain. Get written permission and approval from superiors.
• Check the iron chips exist or not in test area to avoid from damaging tires. If it exists,
do not start to the test without informing superiors.

VEHICLE QUALITY CONTROL TESTS

A) MECHANICAL CONTROLS
• Control all fixings of pins on vehicle.
• Check all the hydraulic lines, pipes, fittings, hoses and positions of them.
• Make sure assembly of backhoe attachment side-shift carriage is proper. Check swing
support shim and swing support rollers.
• Control engine, transmission, fuel tank and connections of them.
• Control hydraulic pump, hydraulic tank, control valve and connections of them.
• Check radiator joints and the assembly dimensions of ventilation hood. For suction
fans, 2/3 of fan thickness must be located inside the hood. For blowing fans 1/3 of fan
thickness must be located inside the hood. Make sure fan assembled at the center of
the hood.

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• Control assembly of radiator, hydraulic cooler, intakes and outlets of them. Make sure
radiator case was anchored to the chassis and there is not any leakage.
• Control the feed tank of radiator.
• Control rear axle ventilation plug and rear axle bolts. Make sure bolts are torqued to
450 Nm (+-45 Nm)
• Check tire air pressures.
• Control the oscillation of front axle and make sure oscillation is same in both sides.
Control the chassis connections of oscillation stop chocks.
• Control assembly of front and rear shaft. Make sure rear shaft clutch directions are on
the same alignment.
• Control assembly of front, rear wheel and axles. Make sure bolts are torqued to 450
Nm (+-45 Nm).
• Control connections and assembly of exhaust system.
• Control air filter components and hose connections and brackets of them.
• Control engine top cover, hood side covers and cabin front chassis isolation.
• Make sure assembly of steering wheel is proper.
• Control loader bucket pin fixing, assembly of hoses, lines and pipes of loader bucket
hydraulic system, front weights.
• Check all hydraulic cylinders and make sure there is no scratch, impact or chrome
deformity on them.
• Control fuel system connections.
• Control assembly of transmission and hydraulic oil cooler hoses.
• Control welding of main components, chassis generally. Make sure there are not any
pores or welding deformations.
• Make sure seat was assembled properly. Control the functions of it.
• Make sure assemblies of hand throttle, throttle lever, extendable dipper pedal are
proper. Control pedal clearances and interlock locking system.
• Control assembly of battery, battery box and the cover of it.
• Make sure assembly of tilt automatic is proper.
• Control assembly of tool box and cover of it.
• Control assembly of compartment, compartment connections and chassis back closure
sheet.
• Control engine connection chocks.

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 • Control the functionality of the compartment doors. Control handles and locks of
them.
• Control cover locks of fuel and hydraulic tanks.
• Make sure left and right steering stopping adjustments are made proper.
• Control compartment roof polyester connection bolts.

B) PRESSURE CONTROLS
• Before performing the pressure controls, start the vehicle and make hydraulic oil
temperature rise to 55 - 60°C by moving hydraulic system components. Hydraulic oil
temperature is controlled from hydraulic hoses and hydraulic tank by infrared
thermometer which is shown in picture 1 and picture 2. Continue this process until
hydraulic oil temperature rise up to desired values.

Picture 1 Picture 2
• Adjust the pilot pressure by observing motion of loader boom. Pilot pressure was
adjusted from adjustment relief which is on the regulation block, shown in picture 3.
Continue this process until loader boom can perform float position. (For 885 backhoe
loader, please consult test control specialist)

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 Picture 3
Make sure pilot pressure is at the level of 27-28 bar by measuring from minimens
coupling which is shown in picture 4. (Pilot pressure is not present in 880 and 883
backhoe loaders)

Picture 4

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• Make sure steering pressure is at the level of 175-180 bar by turning the steering
wheel right direction completely and measuring from minimens coupling which is
shown in picture 5 as number 1.

Picture 5

• Make sure pump 1 pressure at the level of 220 bar by measuring from minimens
coupling which is shown in picture 5 as number 2. Also make sure pump 2 pressure at
the level of 160 bar by measuring from minimens coupling which is shown in picture
5 as number 3. The minimens couplings of pump 1 and pump 2 can be seen clearly on
semi assembled chassis in picture 6.

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 Picture 6

C) LEVEL CONTROLS
• Measure transmission oil by oil dipstick which is shown in picture 7 while engine is
running, gear is at natural position and transmission is at working temperature. Make
sure oil level is between upper mark and below mark on the dipstick.

Picture 7
• Measure engine oil by oil dipstick which is shown in picture 7 and picture 8 after
engine was stopped and waited for 5-6 minutes, while vehicle is parked on flat
surface. Make sure oil level is between upper mark and below mark.

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 Picture 8 Picture 9

• Control the level of coolant and antifreeze after engine is cool down. Make sure the
coolant level should reach the lower end of the filler neck under the cap of the
expansion reservoir which is shown in picture 10, when the coolant is cold.

Picture 10

• Control hydraulic oil level from sight gauge which is shown in picture 11 after vehicle
is parked on flat surface and all attachments are positioned to road travel position.
Make sure hydraulic oil level is on the middle of the sight gauge.

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 Picture 11

• Control hydraulic brake fluid level from the reservoir which is shown in picture 12.

Picture 12

• Check battery acid level.

• Check the level of windshield washer reservoir level which is shown in picture 13.
Make sure washer mixture maintains proper antifreeze.

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 Picture 13

D) LUBRICATION CONTROLS
• Control front and rear axis. Make sure oil ejects from groove which is shown in
picture 14, after plugs are removed while vehicle is parked on level ground.

Picture 14
• Control cer (final reduction) oils. Make sure oil is at the level of oil level line by
controlling from the plugs while vehicle is parked on level ground. Plug and oil level
line are shown in picture 15.

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 Picture 15
• Control the grease fittings of loader bucket pin, backhoe pin and shaft joint. Make sure
all grease fittings were greased before the test.

E) ENGINE SPEED CONTROLS

• Warm up the engine by running for 3 – 5 minutes on idle position, then on 1800 –
2000 rpm for 4 – 5 minutes. Control engine speed after making sure that engine
temperature is at desired values. Control engine speed from motor pulley by
tachometer which is shown in picture 16.

Picture 16

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 • Adjust engine idle speed from idle adjusting screw which is on fuel feed pump and
shown in picture 17, if idle speed is not at set levels. (Idle speed values are informed
on control report)

Picture 17

• Make sure engine full throttle speed is at desired values. (Full throttle speed values are
informed on control report)

NOTE: Vehicle should be washed and rinsed for cleaning up oil and grease which could be
smeared while pressure controls or assembly, before performing the following test processes.
Also make sure bucket stop chocks were adjusted.

F) FUNCTIONAL CONTROLS
• Make sure throttle lever, hand throttle and steering system are functional.
• Make sure braking system is functional. Control service braking system. Make sure
hand brake is functional by performing ramp test.

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 • Make sure all forward and reverse gears are functional. (For 880 and 888 backhoe
loaders all 4 forward and 4 reverse gears, for 883 and 885 backhoe loaders all 4
forward and 3 reverse gears)
• Make sure side-shift carriage is functional by moving it left and right positions
completely.
• Make sure swing support has no contact by testing at different positions.
• Make sure lift cylinders has no contact while they are raised up completely.
• Control the functionality of backhoe right and left operating sticks and locking bolt.
• Control the functionality of loader bucket control stick and locking bolt.
• Control the functionality of tilt automatic.
• Make sure tires do not cause any contact or rubbing.
• Control differential lock.
• Control the anchoring of exhaust pipe. Make sure there is not any gas leakage.
• Control moving of machine by adjusting vehicle to road travel position. Make sure
oscillation which happens while moving, does not cause any contact or rubbing
between tires and vehicle.
• Control crab or round steering. (Only in 888 backhoe loader)
• Test the functionality of the four wheel drive system (4X4) by levitating vehicle with
loader bucket and stabilizers. (Only in backhoe loaders which have four wheel drive
function)

G) HYDRAULIC SYSTEM CONTROLS

• Test tilt cylinders and make sure they are functional. While the test, at the end of the
each move perform relief for 1 – 2 seconds and observe hydraulic system connections.
• Test bucket cylinders and make sure they are functional. While the test, at the end of
the each move perform relief for 1 – 2 seconds and observe hydraulic system
connections.
• Test lift cylinders and make sure they are functional. While the test, at the end of the
each move perform relief for 1 – 2 seconds and observe hydraulic system connections.
• Test stabilizer cylinders and make sure they are functional. While the test, at the end
of the each move perform relief for 1 – 2 seconds and observe hydraulic system
connections.
• Make sure backhoe sideshift slide lock is functional.

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• Test backhoe bucket cylinder and make sure it is functional. While the test, at the end
of the each move perform relief for 1 – 2 seconds and observe hydraulic system
connections.
• Test extendible stick cylinder and make sure it is functional. While the test, at the end
of the each move perform relief for 1 – 2 seconds and observe hydraulic system
connections. Also make sure hydraulic system hoses are not stuck to anywhere. (Only
in backhoe loaders which have extendible boom configuration)
• Test stick cylinder and make sure it is functional. While the test, at the end of the each
move perform relief for 1 – 2 seconds and observe hydraulic system connections.
• Test backhoe boom cylinder and make sure it is functional. While the test, at the end
of the each move perform relief for 1 – 2 seconds and observe hydraulic system
connections.
• Test swing cylinders and make sure they are functional. While the test, at the end of
the each move perform relief for 1 – 2 seconds and observe hydraulic system
connections.
• Examine the vehicle visually while engine is stopped, hydraulic oil is warm,
stabilizers are raised and all attachments are stable. Control oil leakages which could
be occurred while hydraulic system controls and internal leakages. Determine leakages
if available. All cylinders are marked from their rods or any fixed point which is
shown in picture 18, picture 19, picture 20 and keep under supervision for 10 minutes
to state internal leakages. Determine the internal leakages from marked points and
make sure internal leakages of all hydraulic cylinders do not exceed the tolerance
values. (Tolerance values are informed in control report)

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Picture 18 Picture 19

Picture 20

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H) CONTROL OF ELECTRICAL COMPONENTS

NOTE: During all machine test periot, keep all illumination on possition.

• Functionality of ignition key is controlled, to be sure that works properly.

• Functionality of test buton is controlled.
• Engine oil pressure warning lamb and battary charge warning lamb are kontrolled. Be
sure that the lambs turns off after starting the engine.
• Be sure that engine pre heat lamb and park break lamb work preparely.
• Be sure that warning lambs and butons of differential lock and 4x4 are work properly.
• Be sure that loader joy-stick buttons work properly ( pump unload buton, transmision
unload buton, bucket buton)
• Be sure that park break warning horn works properly.
• Be sure that backhoe side-shift slide lock buton and lamb work properly.
• Be sure that engine speed gauge, hourmeter, engine coolant temperature gauge work
properly
• Be sure that fuel level gauge works properly.
• Be sure that beacon lamb and it’s buton works properly.
• Be sure that all front and rear working lambs and their butons work properly.
• Be sure that high beam and flashor work properly.
• Be sure that hazard warning switch works properly.
• Be sure that park lamb and it’s buton work properly.
• Be sure that rear and front window windshield wipers and their switchs work properly.
• Be sure that right-left signal and horn buton work properly.
• Be sure that interior lambs, indicator gauge lambs are works properly.
• Be sure that rear gear wanning horn works properly.

I) VISUAL CONTROLS

• Polyester in cab and floor mat are controlled.

• Front cab lower polyester, back cab lower polyester and mud guard are controlled.
• Out rear mirrors and lift security stick are controlled.

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 • Right , left ledder sheets (steps) and cab windows are controlled, to be sure that no any
strach or fracture on windows. Silicon applications on connections are controlled.
• Noice insulation materials and front hood shade are controlled
• All paintings are controlled, to be sure that there is no where without paintings and
there is no any pour drop or bubbling on paint.
• Be sure that floor mat fixed correctly.
• Controll all labels.
• Operator and maintanance books and toolkit are controlled.

NOMENCLATURE
Main Component : Each main part that consist the machine such as chasis, cab, front boom,
stick boom e.t.c.
Bomometer : Device that shows frrezing point of anti-freeze – water mixture.
Infrared thermometer : Device that measures surface temperature via infrared beam.
Steering pressure : Pressure of steering system (steering system is controlled by steering unit
end enables to move the steering cyliders)
Security stick : The part that avoid front boom to slide down.
Air barometer : Device that measures air pressure of tire.
Hydroulic pump : The hydroulic pump that provides determined level of pressure to the
hydroulic system of the machine.
Manometer : Device that measures hydroulic pressure of fluids.
Minimens : Connection aparatus between hydroulic line and manometer.
Oscilation : In certain degrees of free movement of tracking parts to keep the machine in
stable position.
Pilot pressure : Pressure that enables movement of slide in hidrolic valve.
Pompa 1 pressure : The main pressure of backhoe loader hydroulic system that enables
movement of all cyliders.
Pomp 2 pressure : The support pressure of backhoe loader hydroulic system that enables
movement of all cyliders.
Radiator fluid (coolant) : The fluid composed of water and anti-freeze that prevent the
engine temperature to rise beyond certein degree.

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Relief : To by-bass the flow in order to prevent the hydroulic pressure rise beyond determined
level In any hydroulic system or line. (it is applied on a hydrolik line by continiouing the
motion after the end of movement of any cylinder for 2-3 seconds only, extention in relief
time mey harm your hydroulic system).
Tachometer : Device that measures the number of round per minute of spinning object. (such
as “engine”)
Torkmeter : Device that measures squizing degree (tork) of any pins, nuts.
Oil impurity measuring device : Device that measures particul content of hydroulic oil that
flows in the system of machine.

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