Prodigy Parts Manual Part No. 999-858.01
Table of Contents Parts List and Illustrations Page Number Kits and Routine Maintenance Parts Table...iv Hydraulic Component Location... 1 Engine and Hydraulic Pump Group... 2 Hydraulic Controls and Cowling Group... Lift Arm Assembly... 8 Track Drive System... 12 Frame Group... 1 Decal Group... 16 Bolt Torque Table... 18 Metric Bolt Torque Table... 19 Write your machines Serial Number in the space below for future reference. The serial number is located on the metal tag underneath the manual holder on the left side of the cowel assembly. NOTE: On some earlier models, the Serial Number tag was located inside the cowel assembly. MFG BY: MANUFACTURING, LLC SERIAL NO: 083285 MODEL NO: PART NO: TK216 TK216P Record SERIAL Number here The Serial Number shown on the metal tag contains additional information. When looking up replacement parts in this manual, refer only to the ACTUAL SERIAL NUMBER. 083285 Internal Use Only Actual Serial Number Internal Use Only iii
Routine Maintenance Replacement Parts The following parts should be considered as normal stock part items in your location. Keeping a supply of these items will enable you to keep the Prodigy in full service. Part Name Part Number Air Filter... 17211-Z0A-013 Pre-Filter (Air Filter)... 17218-Z0A-810 Fuel Filter (engine mounted)... 16910-ZE8-015 Fuel Filter (fuel line)... 1591 Hydraulic Filter (up to Serial Number 093160)... 1600 Hydraulic Filter (from Serial Number 093161 to present)... 220620.001 Engine Oil Filter... 1500-PFB-00 Spark Plug... BPR5ES Hydraulic Oil... ISO-68-5 Seal kit for Lift Cylinder... 10270 Seal kit for Tilt Cylinder... 1070 Seal kit for Wheel Motor... L112282.001 Seal kits for Control Valve: Between Section Seal Kit... 1700- Spool Cap Seal Kit... 1700-5 Replacement cartridge for Counterbalance valve... 205219.001 Female Auxiliary Hydraulic Coupler Repair kit... KITN38 Replacement Key... 30009 iv
Hydraulic Component Location 1 8 2 5 7 3 6 1026 Item No Description 1 Hydraulic valve bank, including control handles 2 Hydraulic fi lter 3 Right track drive Left track drive 5 Hydraulic pump 6 Lift arm hydraulic cylinder 7 Attachment tilt hydraulic cylinder 8 Attachment quick couplings (without protective covers) 1
Engine and Hydraulic Pump Group 8 9 20 31 18 29 3 35 33 20 5 23 26 32 1 0 1 21 27 28 6 6 37 39 38 22 25 13 1 36 19 30 17 2 12 7 7 1020 2
Engine and Hydraulic Pump Group Key No. Description Qty Serial No. 221 & above Serial No. 101-220 1 FILTER ASSY, SPIN ON W/ HEAD 1 220620 220620 ENGINE/PUMP ASSY 3 WASHER, FLAT 1/ G5 230310 230310 WASHER, LOCK 5/16 G5 2 230311 230311 5 BOLT, HH M8 X 1.25 1 2396235 2396235 6 BOLT, HH M8 X 1.25 2 239629 239629 7 BOLT, HH M8 X 1.25 2 213269 213269 (Installed upwards through tank) 8 NUT, M8 2 2702013 2702013 9 Sealing Washer for M8 Flange Bolt 3 202300 10 NUT, LOCK M8 X 1.25 ZC 2 2702102 2702102 11 ENGINE AND PUMP ASSY, PARKER 1 3050105 3050100 12 BOLT, SOC 3/8-2 X 1 NF 2 1912371F 250203 13 FITTING 1 2292125 2390681 1 FITTING 1 2296685 219686 15 WASHER 2 230312 17 PUMP 1 21685 L11670 18 BEARING 1 216210 19 FITTING, HB 12 X 12 SAE ORING 90 1 219602 220625 20 EXHAUST GASKET, 2 HP HONDA 2390590.008 2390590.008 21 MUFFLER, KANGA 16 1 2391372 2391372 22 SPARK ARRESTOR 1 2393195A 2393195A 23 SPIDER, RED PLATSOMER 1 23910.003 L115530 2 HOSE, FC619-12 CUT 5 LONG 1 2396895-005.00 2396895-005.00 25 HUB SPLINED 1 209391.001 L115510 26 HUB-KEYED 1 1 209391.00 L115520 27 SCREW, SELF DRILLING 8 X 1/2 HH 2 211995 211995 SLOTTED 28 BOLT, HEX FLANGE M6 X 1.0 213299 213299 29 SQUARE ENGINE SHAFT KEY 1 301037 301037 30 PUMP PRESSURE TUBE, PARKER 1 3050138 3050136 31 COUPLING SPACER 1 305020 3050077 32 ENGINE AND PUMP MOUNT 1 3050206 306002 33 EXHAUST ELBOW 2 L115905.003 L115905.003 3 FUEL LINE, 17 1 2396987.017 2396987.017 35 FUEL FILTER, IN-LINE 1 216695 216695 36 GASKET, 3.2 MM THK FROM KK513 KID 1 L11601 L11601 37 GASKET, 3.2 MM THK FROM KK513 KID 1 L11602 L11602 38 FILTER, HYDRAULIC OIL 1 220620.001 220620.001 39 FITTING 1 210609 210609 0 BONDED SEAL 1 217973 217973 1 BULKHEAD LOCKNUT 1 229785 229785 N/S HYDRAULIC OIL, ISO-68-5 3
Hydraulic Controls and Cowling Group 3 3 0 0 1 3 11 2 6 7 13 2 15 7 17 18 16 1 3 1 2 19 25 27 23 5 22 20 2 9 12 6 35 37 33 32 (B) 30 28 39 36 29 31 3 32(A) 26 1025
Hydraulic Controls and Cowling Group Key No. Description Qty Serial No. 221 & above CONTROLS/COWLING Serial No. 101-220 1 NUT, M12 X 1.75 NYLOCK ZC 2 229778 229778 2 BOLT, CARRIAGE M12 X 1.75 X 0 2 213268 213268 3 WASHER, FLAT M12 ZC 2 2702020 2702020 CONTROL/COWLING ASSEMBLY 5 INSULATION, COWLING 1 OK17251 OK17251 6 NUT, 10-32 MACHINE ZC 2 170808 170808 7 SCREW, MACH PAN 10/32 X 1 2 191091 191091 8 ELBOW, HB 1/ X 1/8 MNPT 1 2296593 2296593 9 WASHER, FLAT 1/ G5 3 230310 230310 10 WASHER, LOCK #10 2 230309 230309 11 THROTTLE, CONTROL -COMPLETE- 1 239613 239613 12 BOLT, HH M8 X 1.25 X 25 ZC 3 2396235 2396235 13 GRIP 2 2396730 2396730 1 INLINE FUEL SHUTOFF VALVE 1 205208 205208 15 FUEL CAP, WITH BREATHER 1 213330 213330 16 CHOKE CABLE 1 21330 21330 17 IGNITION SWITCH, 3 POSITION 1 217970 217970 18 OPERATOR CONTROL WELDMENT 1 3050015 3050015 19 CONTROL VALVE 1 L117280-7 L117280-7 19A CONTROL VALVE SEAL KIT 1 1700- BETWEEN SECTION SEAL KIT 19B CONTROL VALVE SEAL KIT SPOOL CAP SEAL KIT 1 1700-5 20 FITTING 11 2296129 2296129 21 FITTING 1 2296685 2296685 22 COUNTERBALANCE VALVE, PARKER 1 205219 L116600-1 22A COUNTERBALANCE VALVE REPLACEMENT CARTRIDGE 1 205219.001 23 FITTING 1 220636 220602 2 FITTING 1 220637 220637 25 FITTING, TEE 1 3050099 3050099 26 HOSE, AM06-6FJ-6FJ90T 1 3050125 3050125 (Main hydraulic line from pump) 27 HOSE, AM0-6FJ-6FJ90T 1 3050126 3050126 (Counter balance valve to valve bank inlet) 28 HOSE, AM0-6FJ-6FJ (Lift cylinder base end) 1 3050127 3050127 29 HOSE, AM0-6FJ-6FJ (Lift cylinder rod end) 1 3050128 3050128 30 HOSE, AM06-6FJ-6FJ (Left drive motor) 1 3050129 3050129 31 HOSE, AM06-6FJ-6FJ (Left drive motor) 1 3050130 3050130 32 HOSE, AM06-6FJ-6FJ90T (Auxiliary quick connections) 2 3050131 3050131 32A HOSE, AM06-6FJ-6FJ90T, AUXILIARY MALE QUICK CONNECT 32B HOSE, AM06-6FJ-6FJ90T, AUXILIARY FEMALE QUICK CONNECT 33 HOSE, AM06-6FJ-6FJ (Right drive motor) 1 3050132 3050132 3 HOSE, AM06-6FJ-6FJ (Right drive motor) 1 3050133 3050133 5
Hydraulic Controls and Cowling Group (continued) 3 3 0 0 1 3 11 2 6 7 13 2 15 7 17 18 16 1 3 1 2 19 25 27 23 5 22 20 2 9 12 6 35 37 33 32 (B) 30 28 39 36 29 31 3 32(A) 26 1025 6
Hydraulic Controls and Cowling Group (continued) Key No. Description Qty Serial No. 221 & above Serial No. 101-220 35 HOSE, AM0-6FJ-6FJ (Tilt cylinder base end) 1 305013 305013 36 HOSE, AM0-6FJ-6FJ (Tilt cylinder rod end) 1 3050135 3050135 37 HOSE, AM06-6FJ-6FJ90T 1 3050137 3050137 (Main hydraulic return line) 38 ADAPTER, HYDR M16X2 TP MALE X 1 70.96892 70.96892 39 IGNITION WIRING HARNESS 1 305011 305011 (shown with hydraulic hose bundle) 0 ROUND, CONTROL LEVER 2 3050230 3050230 1 ROUND, CONTROL LEVER 1 3050231 3050231 2 ROUND, CONTROL LEVER 2 3050232 3050232 3 KNOB, CONTROL L117270 L117270 TACHOMETER/HOUR METER 1 L12150 L12150 5 FITTING 1 2296685 219686 6 FITTING 1 70.72666 7 KEY 1 30009 30009 7
Lift Arm Assembly 36 2 35 7 37 1 3 9 23 21 2 22 20 16 28 19 13 16 21 27 10 1 6 2 31 12 18 5 29 17 7 3 30 15 11 38 2 8 15 2 1 5 39 0 11 3 0 2 1 5 1021 8
Lift Arm Assembly Key No. Description Qty Serial No. 221 & above Serial No. 101-220 LIFT ARM ASSY 1 NUT, NF 3/-16 ELASTIC STOP 2 22911 22911 2 ACORN NUT 229779 229779 3 BOLT, HH M8 X 1.25 X 50 ZC 2396258 2396258 WASHER, FLAT M20 ZC 2 2398386 2398386 5 WASHER, FLAT M2 ZC 2 2398387 2398387 6 ZERK, 1/8 STR NPT 5000 1 2651850 2651850 7 BOOM ARM PIVOT PIN 1 305005 305005 8 SWIVEL PIN WELDMENT 1 3050070 3050070 9 LIFT ARM ASSEMBLY 1 3050101 3050101 10 CHAIN TENSIONER 1 12620 12620 11 FITTING 2290102 2290102 12 ROLLER CHAIN 1 2290308SAP-063.50 2290308SAP-063.50 13 CONNECTION LINK 1 2290308SAP.001 2290308SAP.001 1 NUT, M1 X 2.00 NYLOCK ZC 1 229780 229780 15 BOLT, HH M8 X 1.25 X 16 ZC 2 2393226 2393226 16 BULKHEAD FITTING 2 210605 210605 17 BOLT, HH M12-1.75 X 75 ZC 1 213272 213272 18 BOLT, HH M1-2.00 X 65 ZC 1 213273 213273 19 BOLT, HH M6 X 1.00 X 12 ZC 2 21327 21327 20 FEMALE QUICK DISCONNECT SOCKET 1 219698 219698 20A FEMALE QUICK DISCONNECT 1 KITN38 REPAIR KIT 21 DUST PLUG FOR FEMALE QUICK 1 219698 219698 DISCONNECT 22 MALE QUICK DISCONNECT PIN 1 219699 219699 23 DUST CAP FOR MALE QUICK 1 219699 219699 DISCONNECT 2 ZERK, 1/8 STR NPT 5000 5 2651850 2651850 25 ZERK, 1/8NPT 90 DEGREE 1 2651855-A 2651855-A 26 ZERK, M6 X 1.00 STR 1 2651857 2651857 27 BOOM ARM WELDMENT 1 3050020 3050020 28 BOOM ARM COLLAR WELDMENT 1 3050032 3050032 29 CHAIN TENSIONER PLATE 1 3050065 3050065 30 SWIVEL PIN, WITH ZERK 1 3050071 3050071 31 SPROCKET WITH ARM WELDMENT 1 3050075 3050075 ATTACHMENT COUPLING ASSEMBLY 33 NUT, ACORN M8 X 1.25 ZC 2 229779 229779 3 WASHER, LOCK M12 ZC 2 2392303 2392303 35 PIN, ROLL 2 270007 270007 36 BOLT, HH M12 X 1.75 X 5 ZC 2 2706562 2706562 GR10.9 37 MALE ADAPTER WELDMENT 1 305000 305000 38 CYLINDER, TILT 2 1 L110261 L110261 38A TILT CYLINDER SEAL KIT 1 1070 (L110261.001) 9
Lift Arm Assembly (continued) 36 2 35 7 37 1 3 9 23 21 2 22 20 16 28 19 13 16 21 27 10 1 6 2 31 12 18 5 29 17 7 3 30 15 11 38 2 8 15 2 1 5 39 0 11 3 0 2 1 5 1021 10
Lift Arm Assembly (continued) Key No. Description Qty Serial No. 221 & above Serial No. 101-220 39 CYLINDER,LIFT 2.5 1 L11061 L11061 39A LIFT CYLINDER SEAL KIT 1 10270 (L11061.001) 0 LIFT CYLINDER PIN 2 L110650 L110650 1 MALE ADAPTER PIN 1 3050055 3050055 2 MALE ADAPTER LOCK 2 305003 305003 3 PLUG, O-RING 1 2291626 2291626 WASHER, M6 X M18 OD ZC 2 2398388 2398388 5 HARDENED WASHER 1 2398382 2398382 6 NUT, M12 x 1.75 THD ZC 1 229772 229772 7 LOCK WASHER 1 230311 230311 11
Track Drive System 1 11 5 9 6, 1 15 12 5 6, 1 16 13 2 8 7 3 10 17 13 11 1022 Key No. Description Qty Serial No. 221 & above Serial No. 101-220 1 TRACK DRIVE COMPONENTS 2 INNER BEARING 2 OK12793.001 OK12793.001 3 OUTER BEARING 2 OK12793.003 OK12793.003 NUT, NF 3/-16 ZC CASTELLATED 2 171227 171227 5 COTTER PIN, 1/8 X 1 1/2 1630 1630 6 FITTING 2399695 2399695 7 DUST CAP 213358 213358 8 SEAL 2 217985 217985 9 DRIVEN HUB WELDMENT 2 3050190 OK12692 10 IDLER HUB WELDMENT 2 3050193 OK12792 11 TIRE AND WHEEL ASSEMBLY 2396138 OK107 11A TIRE 2396138.001 2396138.001 11B TUBE 2396138.002 2396138.002 11C WHEEL 2396138.002 2396138.002 12 NUT, M12 8 229778 229778 13 WHEEL LUG NUTS 20 229783 229783 1 FITTING 2399695 2399695 15 BOLT, HH M12 8 2702090 2702090 16 MOTOR WHEEL 2 L112282 L112282 16A Wheel Motor Seal Kit 1 L112282.001 17 TRACK 2 L11062 L11062 12
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Frame Group 9 5 6 2 5 9 25 2 23 17 1 21 20 12 15 16 29 10 6 30 19 28 10 15 31 22 18 1 102 1
Frame Group Key No. Description Qty Serial No. 221 & above MISC FRAME COMPONENTS Serial No. 101-220 1 FILTER SHIELD INSULATION 1 OK17250 OK17250 2 NUT, NC 5/8-11 ZC G5 2 17001 17001 3 RIVET, ALUM 1/ X 3/ AD88A 1832089 1832089 WASHER, FLAT 1/ G5 5 230310 230310 5 WASHER, FLAT 9/16 1 230317 230317 6 WASHER, LOCK 5/16 G5 1 230311 230311 7 WASHER, LOCK 5/8 G5 2 230320 230320 8 BOLT, HH M8 X 1.25 X 16 ZC 3 2393226 2393226 9 EYEBOLT, 5/8-11 X 1.75 PLATED 3 2393520 2393520 10 BOLT, HH M8 X 1.25 X 25 ZC 1 2396235 2396235 11 BOLT, HH M8 X 1.25 X 12 SS 1 239627 239627 12 MANUAL HOLDER 1 200822 200822 13 CLAMP, 900729-1 1 210369 210369 1 PROTECTIVE PLASTIC COIL SLEEVE 1.5 217975 217975 15 NUT, LOCK M8 X 1.25 ZC 1 2702102 2702102 16 PRODIGY FRAME WELDMENT 1 3050025 3050025 17 HOSE TRAY 1 3050052 3050052 18 HYDRAULIC FILTER SHIELD 1 3050059 3050059 19 MUFFLER GUARD 1 3050076 3050076 20 HYDRAULIC DIP STICK ASSEMBLY 1 3050083 3050083 21 TRACK INSTALLATION TOOL 1 3050109 3050109 22 REAR STEP ASSEMBLY 23 NUT, M12 2 229778 229778 2 WASHER, FLAT M12 ZC 2 239230 239230 25 BOLT, SOC M12 2 213298 213298 26 PIN, ROLL 6MM 2 270007 270007 27 OPERATOR PLATFORM WELDMENT 1 3050097 3050097 28 BATTERY 1 213295 213295 29 BATTERY COVER WELDMENT 1 3050090 3050090 30 BATTERY CABLE, POSITIVE 1 305012 305012 31 BATTERY CABLE, NEGATIVE 1 305013 305013 15
Decal Group 12 7 6 1 9 13 10 2 15 8 11 13 3 2 7 3 8 HIDDEN BEARING 1023 16
Decal Group Key No. Description Qty Serial No. 221 & above Serial No. 101-220 1 KIT, DECAL TRACKED OK18608 2 DECAL, POWERHOUSE PRODIGY LARGE 1 OK18608.001 OK18608.001 3 DECAL, POWERHOUSE PRODIGY SMALL 3 OK18608.002 OK18608.002 DECAL, CONTROL PANEL 1 OK18608.003 OK18608.003 5 DECAL, TK216 1 OK18608.00 OK18608.00 6 DECAL, DO AND DON T 1 OK18608.005 OK18608.005 7 DECAL, HIDDEN BEARING GREASE REG 1 OK18608.006 OK18608.006 8 DECAL, CABLE EYE 2 OK18608.008 OK18608.008 9 DECAL, HOOK 1 OK18608.009 OK18608.009 10 DECAL, MAX FILL LEVEL 1 OK18608.010 OK18608.010 11 DECAL, SWL 220 LBS 1 OK18608.011 OK18608.011 12 DECAL, ENGINE SWITCH 1 OK18608.012 OK18608.012 13 DECAL, DANGER PINCH POINT 2 239683 239683 1 DECAL, WARNING (REFUELING) 1 20003 20003 15 DECAL, HYDRAULIC OIL (ISO) 68 1 20007 20007 17
Torque Table for Grade 2, Grade 5 and Grade 8 Bolts Grade Marking No Mark Grade SAE Grade 2 SAE Grade 5 SAE Grade 8 Size Plain Plated Plain Plated Plain Plated ft. lb. N-m ft. lb. N-m ft. lb. N-m ft. lb. N-m ft. lb. N-m ft. lb. N-m 1/ -20 5.5 7.5.1 5.6 8.5 11.5 6.3 8.5 12 16 9 12 1/ -28 6.3 8.5.7 6. 10 13.6 7.3 9.9 1 19 10 1 5/16-18 12 16 9 12 17 23 13 18 25 3 18 2 5/16-2 13 18 10 1 19 26 1 19 27 37 20 27 3/8-16 20 27 15 20 31 2 23 31 60 33 5 3/8-2 23 31 17 23 35 7 26 35 9 66 37 50 7/16-1 32 3 2 33 50 68 37 50 70 95 52 70 7/16-20 36 9 27 37 55 75 1 56 78 106 58 79 1/2-13 9 66 37 50 76 103 57 77 106 1 80 108 1/2-20 55 75 1 56 85 115 6 87 120 163 90 122 9/16-12 70 95 53 72 109 18 82 111 15 209 115 156 9/16-18 79 107 59 80 122 165 91 123 172 233 129 175 5/8-11 97 132 73 99 150 203 112 152 212 287 159 216 5/8-18 110 19 83 113 170 230 128 17 20 325 180 2 3/ -10 173 235 129 175 266 361 200 271 376 510 282 382 3/ -16 192 260 1 195 297 03 223 302 20 569 315 27 7/8-9 166 225 125 169 30 583 322 37 606 822 5 615 7/8-1 18 29 138 187 7 63 355 81 668 906 501 679 1-8 250 339 188 255 6 873 83 655 909 1232 682 925 1-12 27 371 205 278 700 99 529 717 995 139 76 1011 1-1 280 380 210 285 721 977 51 733 1019 1381 76 1036 1-1/8-7 35 80 266 361 79 1076 596 808 1288 176 966 1310 1-1/8-12 397 538 297 03 890 1207 668 906 1 1958 1083 168 1-1/ -7 500 678 375 508 1120 1518 80 1139 1817 263 1363 188 1-1/ -12 553 750 15 563 121 1682 930 1261 2012 2728 1509 206 1-3/8-6 655 888 91 666 170 1993 1102 19 2382 3229 1787 223 1-3/8-12 76 1011 559 758 1672 2267 125 1700 2712 3677 203 2757 1-1/2-6 870 1179 652 88 1950 26 162 1982 3161 285 2371 321 1-1/2-12 979 1327 73 995 219 297 165 2230 3557 822 2668 3617 1028 18
Metric Torque Table for Grade 5.6, Grade 8.8 and Grade 10.9 Bolts Grade Marking MFG 5.6 MFG 8.8 MFG 10.9 Grade 5.6 8.8 10.9 Size ft. lb. N-m ft. lb. N-m ft. lb. N-m 1 1. 2.3 3.1 3.2.3 5 2 2.7.6 6.2 6.3 8.6 6 3..6 8.2 11 11 15 8 8.1 11 19 26 27 36 10 16 22 38 52 53 72 12 28 38 66 90 92 12 1 60 10 11 16 198 16 69 9 159 215 225 305 18 96 130 221 300 310 20 20 136 18 31 26 35 590 22 18 250 20 570 590 800 2 232 315 538 730 752 1020 27 37 70 785 1065 1106 1500 30 65 630 1069 150 1512 2050 33 63 860 153 1970 203 2770 36 811 1100 1796 235 2625 3560 19
Compact Power Inc. P.O. Box 0 Fort Mill, SC 29716 Phone: 800-76-9673 Fax: 803-58-2762 Web Site: http://www.cpiequipment.com/ Part No. 999-858.1