Description

Manitou T502TC-D, T502TC-DSB, T602TC-D, T602TCP-D, T602TCP-DXL 1996 Parts Catalog

If you are ordering parts for a Manitou T502TC-D, T502TC-DSB, T602TC-D, T602TCP-D, or T602TCP-DXL and you are guessing part numbers from a third-party database, stop. That is how you get a hydraulic filter that does not fit or a transmission seal that leaks within 50 hours. This is the original 1996 factory Parts Catalog – 182 pages of exploded diagrams, filter charts, and part numbers that match the parts on your lift truck. No reprints, no copied-from-some-other-manual garbage. K-D Manitou, Inc. published this for a reason: so you order the right piece the first time.

I have torn down enough Ford powertrains in San Antonio to know that the difference between a 421602 oil filter and a generic substitute is the difference between 150 hours of clean oil and a spun bearing. This catalog gives you the factory part number, the quantity required, and the exact model applicability. Page 3 of the PDF (the inside cover) shows the FILTER CHART with eight filters, part numbers, and replacement intervals. Engine oil filter 421602 – replace every 150 hours. Air filter cartridge 421468 – clean at 150, replace at 450. That kind of data keeps your Manitou running.

You need to understand the naming scheme before you start flipping pages. The model number on the nameplate tells you everything: T502TC-D means 5,000 lb lift capacity, torque converter transmission, diesel. T602TCP-DXL is 6,000 lb, poultry package, low cab. The catalog covers serial numbers T5020058, T6020625, T8020167, T10020146 and above (excluding S/N T6020630 and T6020631). If your truck falls outside that range, you need a different manual – but for those numbers, this is your bible.

Filter Chart: Keep Your Hydraulics Clean

The filter chart on page 3 lists ten serviceable items. Transmission oil filter 425657 – 450 hours. Hydraulic oil filter cartridge 422141 – 450 hours. Hydraulic suction screen 424764 – 900 hours, replace if damaged. That suction screen is buried under the hydraulic tank; you do not want to pull it twice because you guessed the wrong part number. The chart also shows the part number for the vaculator (1.5″ dia: 426199, 3″ dia: 421471) – cheap items that most parts houses do not stock. Having the factory number saves you a day of cross-referencing.

This section is why I tell young techs: stick to OEM documentation. Aftermarket catalogs lump filters from different years into one table and you end up with a fuel filter that has the wrong micron rating. Not here. Each line has a clean interval and a replace interval. The air filter safety cartridge 421473 – replace every 900 hours. That is the inner element that catches what the main cartridge misses. Skip it and you pull dirt into the turbo. Page 3 has all ten items laid out with the illustration number referencing the diagram above.

Parts Index: Navigating the 182 Pages

The PARTS INDEX at the front of the manual lists every illustration by group. You find the assembly – say, the Ford transmission – then flip to that section. Each illustration page has item numbers; the corresponding table gives part number, description, quantity, and which models use that part. Common hardware (nuts, bolts, washers) must be replaced with same or better grade zinc hardware. K-D Manitou says that right in the GENERAL INFORMATION section on page 4 of the PDF. That is not a suggestion – that is a requirement to maintain load ratings. Grade 8 bolt in a grade 5 application? Fine. Grade 5 in a grade 8 hole? You get a failure.

When you call the dealer for a part, you need the truck model number, serial number, powertrain model number, mast model number, mast serial number, engine number, attachment model number, and attachment serial number. Page 4 lists all of them. Write them on the inside cover of this manual and you never waste a phone call. The manual also includes a Ford transmission production code location (right side of transmission, shown in the diagram on page 5). That code ties the transmission to the specific parts listing.

General Information: What the Manual Expects You to Know

The GENERAL INFORMATION section spells out the purpose: illustrations for identifying and ordering lift truck parts. It warns that illustrations are a general description and may not show exact shape or detail. That is fine – the part number is what matters. K-D Manitou also notes that new models are released and part numbers may supersede. Always verify with the Parts Department if you are unsure. But if you have the 1996 catalog, that part number is the starting point. The manual covers the T502TC-D, T502TC-DSB, T602TC-D, T602TCP-D, T602TCP-DXL, plus the T802TC-D and T1002TC-D (those two are not listed in the primary keyword but are included in the same catalog). The CATALOG B242 dated R/10-96 is the revision.

One thing I appreciate: the manual uses Imperial units throughout. Oil filter replacement intervals in hours, not kilometers. That matters when you are working on a forklift that has been in a Texas warehouse since 1996. You follow the hours schedule and your truck stays reliable.

3 Reasons to Choose OEM Documentation

First, aftermarket parts catalogs often merge multiple model years and get the part numbers wrong. I have seen a 1996 T602TC-D listed with a 1998 transmission filter because the database lumped them together. This catalog is specific to the 1996 model year with the Ford powertrain.

Second, the diagrams show the exact orientation of seals, bearings, and filters. The transmission filter 425657 is shown as a spin-on canister – but if you buy a generic replacement with a different thread pitch, it cross-threads and leaks. The OEM part number eliminates that risk.

Third, the manual includes the serial number breakpoints. The note on page 1 excludes S/N T6020630 and T6020631. Those two trucks might have different parts. If you order based on a generic catalog without that exclusion, you get wrong parts.

Does This Manual Cover the Fuel System?

Yes – the fuel filter (cartridge type) part number 421206 is listed on the filter chart. But this is a parts catalog, not a service manual. It gives you the part number and quantity, not installation torque or bleeding procedures. For those procedures, you need a separate service manual. Pair this with the factory repair manual for the Ford diesel powertrain – the parts catalog ensures you buy the correct components before you start the job.

If you want to understand the theory behind the diesel engine in your Manitou, this Wikipedia article on diesel engines gives background on compression ignition cycles. Not necessary for ordering parts, but useful if you are learning.

FAQ

Can I use this catalog for a T802TC-D or T1002TC-D?

Yes. The manual covers T802TC-D and T1002TC-D as well, with serial number ranges listed on page 1.

What if my truck serial number is below T5020058?

This catalog applies to S/N T5020058 and above (excluding T6020630 and T6020631). For earlier serial numbers, contact K-D Manitou or find the correct earlier manual. Do not guess – wrong part numbers lead to downtime and safety hazards.

I have been turning wrenches for 28 years. Every time I see a technician ordering parts without a factory catalog, I know there is a 50% chance the part will be wrong. This 182-page OEM parts catalog eliminates that gamble. Access the Factory Manual and keep it on your tablet or printed in the toolbox. Your Manitou T502TC-D, T502TC-DSB, T602TC-D, T602TCP-D, or T602TCP-DXL deserves the right parts.

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