Core Harvester Adapter Kit

Retrofits Cushman® Core Harvester® Models 4119652, 890009, 894754, and 2701530 to the Heavy-Duty Workman® Vehicles

Model No. 44242-Serial No. and Up

Setup

Preparing for the Install

Important: The machine must have the 2/3 or full truck bed installed on the machine.

Important: Machines with serial numbers 239999999 and below must have the remote hydraulic control kit installed.Machines with serial numbers 240000000 and above must have the high flow hydraulic kit installed.

  1. Park the machine on a level surface.

  2. Engage the parking brake.

  3. Shut off the engine and remove the key from the key switch.

  4. Read and become familiar with the Operator’s Manual that you received with the core harvester.

Drilling the Mounting Holes

Drilling the Mounting Holes on a Full Bed

Perform this procedure only if required.

  1. Locate and mark the hole location on the bed (Figure 1).

    g195093

    Figure 1

    1. Front of the machine
    2. 1.6 cm (5/8 inch)
    3. 2.5 cm (1 inch)
    4. 66.3 cm (26.1 inches)
    5. 29.8 cm (11-3/4 inches)
    6. 13/32 inch diameter hole

  2. Use a 13/32 inch drill bit and drill a hole at the locations that you marked (Figure 1).

Drilling the Mounting Holes on a 2/3 Bed

Perform this procedure only if required.

  1. Locate and mark the hole location on the bed (Figure 2).

    g195104

    Figure 2

    1. Front of the machine
    2. 1.6 cm (5/8 inch)
    3. 2.5 cm (1 inch)
    4. 9.8 cm (3.86 inches)
    5. 29.8 cm (11-3/4 inches)
    6. 13/32 inch diameter hole

  2. Use a 13/32 inch drill bit and drill a hole at the locations that you marked (Figure 2).

Drilling the Hose Support Holes

Perform this procedure only if required.

  1. Locate and mark the hole location on the bed (Figure 3).

    g195410

    Figure 3

    1. 1.6 cm (5/8 inch)
    2. 48.3 cm (19 inches)
    3. 40.6 cm (16 inches)
    4. 7.6 cm (3 inches)
    5. Front of the machine

  2. Use a 13/32 inch drill bit and drill a hole at the locations that you marked (Figure 3).

Mounting the Harvester

Parts needed for this procedure:

Mounting plate (HD/HDX)1
Mounting plate (3000/4000)1
Mounting bracket1
Bolt (5/16 x 2-3/4 inches)2
Washer (3/8 inch)4
Lock washer (5/16 inch)2
Nut (5/16 inch)2
Bolt (3/8 x 1-3/4 inches)2
Washer (7/16 inch)2
Lock washer (3/8 inch)2
Nut (3/8 inch)2

Installing the Mounting Bracket

  1. Use the 2 bolts (5/16 x 2-3/4 inches), washers, lock washers, and nuts to secure the upper portion of the mounting bracket to the harvester frame (Figure 4).

    g038550

    Figure 4

    1. Bolt (5/16 x 2-3/4 inches)
    2. Washer (3/8 inch)
    3. Mounting bracket
    4. Harvester frame
    5. Lock washer (5/16 inch)
    6. Nut (5/16 inch)

  2. Use the 2 bolts (3/8 x 1-3/4 inches), washers, lock washers, and nuts to secure the lower portion of the mounting bracket to the harvester frame (Figure 5).

    g038551

    Figure 5

    1. Nut (3/8 inch)
    2. Lock washer (3/8 inch)
    3. Washer (7/16 inch)
    4. Mounting bracket
    5. Harvester frame
    6. Bolt (3/8 x 1-3/4 inches)

Mounting the Core Harvester to the Machine

Parts needed for this procedure:

Bolt (1/2 x 1-1/4 inches)3
Bolt (1/2 x 1 inch)1
Flat washer (1/2 inch)4
Lock washer (1/2 inch)4
Nut (1/2 inch)3

Mounting the Frame to the Mounting Plate

Series 3000 and 4000

  1. Use the 3 bolts (1/2 x 1-1/4 inches), flat washers, lock washers, and nuts to secure the mounting plate to the mounting bracket (Figure 6).

    g038552

    Figure 6

    Core Harvester and Frame are not Shown

    1. Nut (1/2 inch)
    2. Lock washer (1/2 inch)
    3. Mounting plate
    4. Flat washer (1/2 inch)
    5. Bolt (1/2 x 1 inch)
    6. Bolt (1/2 x 1-1/4 inches)
    7. Mounting bracket

  2. Use the bolts (1/2 x 1 inch), nuts, and lock washers to secure the mounting bracket to the mounting plate (Figure 6).

Mounting the Frame to the Mounting Plate

Series HD and HDX

  1. Use the 3 bolts (1/2 x 1-1/4 inches), flat washers, lock washers, and nuts to secure the mounting plate to the mounting bracket (Figure 7).

    g195040

    Figure 7

    Core Harvester and Frame are not Shown

    1. Nut
    2. Lock washer (1/2 inch)
    3. Mounting plate
    4. Flat washer (1/2 inch)
    5. Bolt (1/2 x 1 inch)
    6. Mounting bracket
    7. Bolt (1/2 x 1-1/4 inches)
    8. Flat washer (9/16 inch)

  2. Use the bolts (1/2 x 1 inch), nuts, and lock washers to secure the mounting bracket to the mounting plate (Figure 7).

Modifying the Core-Harvester Frame

Important: Perform this procedure if necessary.

  1. Ensure that there is clearance between the core-harvester frame and the front tire when you turn them from side to side.

  2. If required, use a cutting tool to remove the corner on the core-harvester frame to eliminate the interference with the front tire (Figure 8).

    g195092

    Figure 8

    1. 6.4 cm (2-1/2 inches)
    2. Flush at the inner angle
    3. Core-harvester frame

Installing the Handle Extension

Parts needed for this procedure:

Handle extension 1
Bolt (1/4 x 1-1/2 inches)1
Lock washer (1/4 inch)1
Nut (1/4 inch)1

  1. Remove and set aside the grip from the handle on the core harvester (Figure 9).

    g195091

    Figure 9

    1. Grip
    2. Handle extension
    3. Bolt (1/4 x 1-1/2 inches)
    4. Core-harvester handle
    5. Lock washer (1/4 inch)
    6. Nut (1/4 inch)
    7. Distance from end (1 inch)

  2. Drill a 9/16 hole, 2.5 cm (1 inch) from the end hole of the core-harvester handle (Figure 9).

  3. Use the bolt (1/4 x 1-1/2 inches), lock washer, and nut to secure the handle extension to the core-harvester handle (Figure 9).

  4. Slide the grip onto the handle extension (Figure 9)

Installing the Hose Retainer

Parts needed for this procedure:

Hose retainer3
Bolt (3/8 x 1 inch)3
Lock washer (3/8 inch)3
Nut (3/8 inch)3
Hose retainer (2-1/2 inches)3

Use the 3 bolts (3/8 x 1 inch), washers, and lock washer to secure the hose retainer to the bed (Figure 10).

g195432

Figure 10

  1. Bed
  2. Nut (3/8 inch)
  3. Lock washer (3/8 inch)
  4. Hose retainer (2-1/2 inches)
  5. Bolt (3/8 x 1 inch)

Installing the Manual Tube

Parts needed for this procedure:

Manual tube1
R-clamp2

  1. Remove and set aside the existing hardware on the core-harvester elevator shown in Figure 11.

    g195146

    Figure 11

    1. Core-harvester elevator
    2. R-clamp
    3. Manual tube
    4. Existing hardware

  2. Use the existing hardware to loosely install the 2 R-clamps to the core-harvester elevator (Figure 11).

  3. Insert the manual tube into the R-clamps.

  4. Tighten the loose hardware to secure the manual tube to the core-harvester elevator.

Mounting Brackets to the Conveyor

Parts needed for this procedure:

Upper bracket1
Lower bracket1
Hose mount1
Bolt (3/8 x 1 inch)8
Lock washer (3/8 inch)8
Flat washer (3/8 inch)8
Nut (3/8 inch)8
Hose retainer (2-1/2 inches)1

  1. Use the existing hardware to secure the conveyor to the upper bracket (Figure 12).

    g191984

    Figure 12

    1. Conveyor assembly
    2. Existing bolt
    3. Existing washer
    4. Upper mount
    5. Existing washer
    6. Existing nut

  2. Use the 2 bolts (3/8 x 1 inch), washers, and nuts to secure the lower bracket to the upper bracket (Figure 13).

    g191985

    Figure 13

    1. Upper bracket
    2. Nut (3/8 inch)
    3. Flat washer (3/8 inch)
    4. Lower bracket
    5. Bolt (3/8 x 1 inch)

  3. Use the 6 bolts (3/8 x 1 inch), washers, and nuts to secure the conveyor to the side of the bed (Figure 14).

    g192118

    Figure 14

    Conveyor assembly is not shown

    1. Nut (3/8 inch)
    2. Lock washer (3/8 inch)
    3. Flat washer (3/8 inch)
    4. Bed
    5. Conveyor mount
    6. Bolt (3/8 x 1 inch)
    7. Flat washer (3/8 inch)
    8. Hose retainer

Checking the Inflation

  1. Inflate the air shock on the machine to level the bed.

    Important: Do not exceed 1034 kPa (150 psi) air pressure when you inflate the air shock.

  2. Ensure that the castor tire on the core harvester is inflated to 69 to 82 kPa (10 to 12 psi)

Installing the Hydraulic Components—For Models Serial No. 240000001 and Above

Parts needed for this procedure:

90° fitting (5/8 x 1/2 inch)1
Straight fitting2
Hydraulic hose A—254 cm (100 inches, 8 FJ to 6 MP)1
Hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP)1
Hose cover—122 cm (48 inches)1
Hose cover—147 cm (58 inches)1
Hose cover—224 cm (88 inches)1

Connecting the Hydraulic Hoses

Note: The machine must have the high flow hydraulic control kit (Model No. 07228 or Model No. 07316) installed.

  1. Install the hose cover 147 cm (58 inches) to the hydraulic hose A—254 cm (100 inches, 8 FJ to 6 MP) as shown in Figure 15.

    g191967

    Figure 15

    1. Elevator-motor hose (port A)
    2. Hydraulic motor
    3. 90° fitting (5/8 x 1/2 inch)
    4. Hydraulic hose A—254 cm (100 inches, 8 FJ to 6 MP)
    5. Hose cover—147 cm (58 inches)

  2. Install one end of the 90° fitting (5/8 x 1/2 inch) to the hydraulic motor and the other end to the hydraulic hose A—254 cm (100 inches, 8 FJ to 6 MP) as shown in Figure 15.

  3. Connect the hydraulic hose included with the core harvester to the IN port on the conveyor motor (Figure 15).

Connecting the Elevator Motor

  1. Install the hose cover 122 cm (48 inches) over the hydraulic hose included with the core harvester (Figure 16).

    g191854

    Figure 16

    1. Elevator motor
    2. Port A
    3. Hydraulic hose from IN port on conveyor motor (supplied with core harvester)
    4. Port B
    5. Hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP) from workman quick coupler (port B )
    6. Hose cover—122 cm (48 inches)
    7. Hose cover—224 cm (88 inches)

  2. Install the hose cover 224 cm (88 inches) over the hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP) as shown in (Figure 16).

  3. Connect the hydraulic hose included with the core harvester to port A on the elevator motor (Figure 16).

  4. Connect the hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP) from the port T quick coupler on the workman to port B on the elevator motor (Figure 16).

  5. Slide the hose covers toward the elevator motor.

Connecting the Hydraulic Hoses to the Machine

Warning

Hydraulic fluid escaping under pressure can penetrate skin. Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury, or gangrene may result.

  • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid.

  • Use cardboard or paper to find hydraulic leaks; never use your hands.

Important: Workman quick coupler (port P) is under pressure when the high flow-hydraulic switch is in the ON position.

  1. Securely install the straight coupler (3/8 NPT) to the hydraulic hose 254 cm (100 inches, 8 FJ to 6 MP) as shown in Figure 17.

    g189299

    Figure 17

    1. Hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP)
    2. Straight coupler (3/8 NPT)
    3. Workman quick coupler (port P)
    4. Workman quick coupler (port T)
    5. Straight coupler (3/8 NPT)
    6. Hydraulic hose A—254 cm (100 inches, 8 FJ to 6 MP)

  2. Securely install the straight coupler (3/8 NPT) to the hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP) as shown in Figure 17.

  3. Connect the hydraulic hose to the machine.

Important: Always cover the connectors when you disconnect them to prevent damaging the hydraulic system.

Installing the Hydraulic Components—For Models with Serial No. 239999999 and Below

Parts needed for this procedure:

Hydraulic motor—Acquired separately (Part No. 92-4240)1
Seal—Acquired separately (Part No. 92-4329)1
Elbow—Acquired separately (Part No. 01-201-4210)2
Barb fitting—Acquired separately (Part No. 01-201-4500)1
Tee fitting—Acquired separately (Part No. 01-201-4510)1
Fitting cap—Acquired separately (Part No. 01-201-4520)1
Hydraulic hose—Acquired separately (Part No. 01-312-5610)1
Hydraulic coupler1
90° fitting (5/8 x 1/2 inch)1
Hydraulic hose A—254 cm (100 inches, 8 FJ to 6 MP)1
Hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP)1
Hose cover—122 cm (48 inches)1
Hose cover—147 cm (58 inches)2
Hose cover—224 cm (88 inches)1

Additional parts are required to install this kit to a machine with a Serial No. 239999999 and below. You can obtain the additional parts through your Toro dealer.

Connecting the Hydraulic Hoses

Note: The machine must have the remote hydraulic control kit installed.

Warning

Hydraulic fluid escaping under pressure can penetrate skin. Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury, or gangrene may result.

  • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid.

  • Use cardboard or paper to find hydraulic leaks; never use your hands.

  1. Remove the hydraulic motor (Part No. 832401) that is install on the core harvester.

  2. Install the hydraulic motor (Part No. 92-4240).

  3. Install the hose cover 147 cm (58 inches) to the hydraulic hose (Part No. 01-312-5610) as shown in Figure 18.

    g189287

    Figure 18

    1. Elevator-motor hose from (port A)
    2. Hose cover—147 cm (58 inches)
    3. Hydraulic hose—(Part No. 01-312-5610)
    4. 90° fitting (5/8 x 1/2 inch)
    5. Hydraulic motor—(Part No. 92-4240)
    6. Elbow fitting—(Part No. 01-201-4210)
    7. Hydraulic hose A—254 cm (100 inches, 8 FJ to 6 MP)
    8. Hose cover—147 cm (58 inches)

  4. Install the hose cover 147 cm (58 inches) to the hydraulic hose A—254 cm (100 inches, 8 FJ to 6 MP) as shown in Figure 18.

  5. Install one end of the 90° fitting (5/8 x 1/2 inch) to the hydraulic motor (Part No. 92-4240) and the other end to the hydraulic hose (Part No. 01-312-5610) as shown in Figure 18.

  6. Install one end of the Elbow fitting (Part No. 01-201-4210) to the hydraulic motor (Part No. 92-4240) and the other end to the hydraulic hose 254 cm (100 inches, 8 FJ to 6 MP) as shown in Figure 18.

  7. Connect the hydraulic hose included with the core harvester to the IN port on the conveyor motor (Figure 18).

  8. Slide the hose covers toward the hydraulic motor.

Connecting to the PTO

  1. Install the tee fitting to the power takeoff (PTO) on the machine (Figure 19).

    g189332

    Figure 19

    1. Return hose from filter
    2. Hose clamp
    3. Barb fitting—(Part No. 01-201-4500)
    4. Tee fitting—(Part No. 01-201-4510)
    5. Hydraulic hose—(Part No. 01-312-5610)
    6. Fitting cap—(Part No. 01-201-4520)
    7. Power takeoff (PTO)
    8. Hydraulic port

    Note: Connect the tee fitting (Part No. 01-201-4510) to the hydraulic port if the machine does not have a PTO drive.

  2. Slide the hose clamp over the filter-return hose (Figure 19).

  3. Insert the barb fitting (Part No. 01-201-4500) into the filter-return hose (Figure 19).

  4. Use the hose clamp to secure the barb fitting (Part No. 01-201-4500) to the filter-return hose (Figure 19).

  5. Connect the hydraulic hose (Part No. 01-312-5610) to the tee fitting (Part No. 01-201-4510) as shown in Figure 19.

    Important: Ensure that all the connectors are free of debris before you make the connection.

Important: Always cover the connectors when you disconnect them to prevent damage to the hydraulic system.

Connecting the Elevator Motor

  1. Install the hose cover 122 cm (48 inches) over the hydraulic hose included with the core harvester (Figure 20).

    g191854

    Figure 20

    1. Elevator motor
    2. Port A
    3. Hydraulic hose from IN port on conveyor motor (supplied with core harvester)
    4. Port B
    5. Hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP) from workman quick coupler (port B)
    6. Hose cover—122 cm (48 inches)
    7. Hose cover—224 cm (88 inches)

  2. Install the hose cover 224 cm (88 inches) over the hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP) as shown in Figure 20.

  3. Connect the hydraulic hose included with the core harvester to port A on the elevator motor (Figure 20).

    Important: Ensure that all the connectors are free from debris before you make the connection.

  4. Connect the hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP) from the port B quick coupler on the workman to port B on the elevator motor (Figure 20).

  5. Slide the hose covers toward the elevator motor.

Connecting the Hydraulic Hoses to the Machine

Warning

Hydraulic fluid escaping under pressure can penetrate skin. Fluid injected into the skin must be surgically removed within a few hours by a doctor familiar with this form of injury, or gangrene may result.

  • Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid.

  • Use cardboard or paper to find hydraulic leaks; never use your hands.

Important: Workman quick coupler (port B) is under pressure when the remote hydraulic is in the ON position.

  1. Ensure that the remote-hydraulic lever is set to the OFF position.

  2. Install the quick coupler included with the core harvester to the hydraulic hose A—254 cm (100 inches, 8 FJ to 6 MP) that you connected to the motor (92-4240) as shown in Figure 21.

    g189299

    Figure 21

    1. Hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP)
    2. Hydraulic coupler (3/8 NPT included with kit)
    3. Workman quick coupler (port B)
    4. Workman quick coupler (port A)
    5. Hydraulic coupler (3/8 NPT included with core harvester)
    6. Hydraulic hose A—254 cm (100 inches, 8 FJ to 6 MP)

  3. Install the quick coupler included with the kit to the hydraulic hose B—330 cm (130 inches, 8 MP to 6 MP)

  4. Connect the hydraulic hose to the machine.

Important: Always cover the connectors when you disconnect them to prevent damage to the hydraulic system.

Checking the Hydraulic Fluid

Important: The hydraulic system on the machine operates on Dexron III automatic transmission fluid. The hydraulic fluid in the core harvester must be the same or compatible fluid. Damage occurs when you use non-compatible fluid.

  1. Ensure that the hydraulic fluid in the core harvester is compatible with the hydraulic fluid in the machine.

  2. Ensure that the packing brake is engaged and start the machine.

  3. Operate the hydraulic system.

  4. Check the level of the hydraulic fluid and add if required; refer to the Operator's Manual for the machine.

Checking for Interference

  1. Ensure that the packing brake is engaged and start the machine.

  2. Ensure that the conveyor is aimed toward the center of the bed.

  3. Raise and lower the bed to ensure that the it does not interfere with the elevator.

  4. Ensure that the hydraulic hoses are not pinch or pulled when you raise and lower the bed.

Schematics

Hydraulic Schematic for Workman Models Prior to Serial Number 239999999

g011909

Hydraulic Schematic for Workman Models Serial Range 240000001 and Up

g011908