Description

BT SPS1.35, SPS1.6, SPS1.35L, SPS1.6L 1997 Service Manual

If you’ve ever fought a forklift that won’t lift, chased a phantom electrical fault, or torqued a bolt on a guess because the aftermarket PDF you obtained cuts off at page 87, you know exactly why BT SPS1.35, SPS1.6, SPS1.35L, SPS1.6L 1997 Service Manual belongs on your bench. I’ve been wrenching since before most of you were born, and I can tell you right now: nobody builds a lift truck like BT, and nobody documents them like the factory. This is the original 248-page service manual, not some third-party rehash with missing torque values and blurry schematics.

The manual covers four BT models off the same platform — SPS1.35, SPS1.6, SPS1.35L, SPS1.6L — built with nominal load capacities of 1.35 and 1.6 tons. The ‘L’ versions are the same machine but with a longer wheelbase for tighter turning radius if you’re working narrow aisles. If you need the exact dimensions for clearances, Generell produktinformation section lists them in millimeters: for the SPS1.35L, overall length at fork face, turning radius, mast height lowered — all of it. You’ll need that data before you jam a truck into a trailer or a rack row.

Truck Data and Main Components

Section M2 (Generell produktinformation version 1 & 2) gives you the full breakdown of components: the free-view mast, hydraulic valve bank, 24V battery with multiple Ah ratings, the swing-out hood for service access, the safety pedal with automatic parking brake, the adjustable steering console, and the combined drive motor / gearbox assembly. It also lists every fuse by BT part number — the 10A control fuse (BT 122308-100), the 20A steering fuse (BT 122308-200), the 160A drive motor fuse (BT 29223), and the 200A pump motor fuse (BT 29673). If you pull a fuse and it’s melted, you know exactly which circuit to trace.

What Torque Specs Are Included?

The Tekniska service data section (M4, dated 1996-11-08) contains the factory torque values for every critical fastener — drive unit mounting bolts, wheel nuts, mast anchor bolts, hydraulic line fittings, and fasteners on the steering motor and pump motor. You are not going to find these numbers in a Chilton’s book for a car. Lift trucks live under a shock load every time they pick up a pallet. Over-torque a mast bolt and you stress the casting; under-torque it and it can shear. The manual uses Nm, so keep a converter handy if your clicker is in ft-lbs. Page 26 in the original file holds the torque reference table for the drive axle — I’d laminate that page if I were you.

3 Key Sections for Preventive Maintenance

Three sections under the ‘P’ (Preventive Maintenance) grouping save you from breakdowns: Underhållsschema (maintenance schedule), Olje- och fettspecifikation (oil and grease specs), and Inledning, underhåll (intro to maintenance). The schedule runs by operating hours — daily checks, 50-hour, 200-hour, 500-hour, and 1000-hour intervals. The oil spec table tells you exactly which hydraulic fluid, gear oil, and grease grade BT approved. Most shops use whatever cheap 32-weight oil they have on the shelf. That’s how you burn out a pump. Don’t be that shop.

SPS1.35 Service Intervals: What the Manual Covers

For the SPS1.35, the Underhållsschema lists every check point: battery electrolyte level, hydraulic oil level and leakage, brake function, tire condition, steering operation, and electrical connections. The manual also includes the Instruktionsbok (operator’s manual) section with the correct way to operate the safety pedal — a foot switch on the left that the driver must press before the truck will drive. If you’re troubleshooting a ‘no-drive’ condition and the operator swears they’re pressing the pedal, go straight to page 1 of that section and test the switch continuity. Nine times out of ten it’s a worn contact.

Drivaggregat: Drive Unit Rebuild Procedure

Section S2 (2550) — Drivaggregat/v — walks you through removal and overhaul of the combined drive motor, gearbox, and brake assembly. It lists required tooling: a puller for the drive wheel hub, a seal driver kit for the output shaft seal, and a torque wrench capable of 150–250 Nm. The procedure includes step-by-step disassembly, bearing preload adjustments, and a leak test after reassembly. I’ve done three of these on SPS1.6L units; if you skip the preload check, the drive gears whine and fail inside 500 hours. Follow the spec.

Source Authenticity: OEM vs Aftermarket

This is not a scan of a scan of a photocopied manual that someone glued together from a dealer binder. It is the original BT Industries AB publication, dated 1997-04-28, with part number 156136-020. The document structure follows BT’s Master Service Manual system: each page is labeled with a section code (M, P, S, O), an F-code for specific documentation, and a T-code for the exact truck model. Every page has a version number and issued date. If you ever call BT technical support, they will ask for your manual version. The aftermarket manuals don’t have that information. This one does. Related manuals for other BT models: BT SPE125 SPE160 SPE125L SPE135S SPE160L 2007 Service Manual | OEM Forklift Repa”>BT SPE125 SPE160 2007 Service Manual, BT Master Service Manual Introduction SL”>BT Master Service Manual Introduction SL, and BT Master Service Manual Index Models OP 1000SE/OPW 1200HSE”>BT Master Service Manual OP 1000SE. For external reference on transmission fundamentals, a read of Manual Transmission”>Manual Transmission basics can help if you’re also working on other equipment.

Frequently Asked Questions

Does this manual cover the electrical wiring diagrams for the SPS1.6L?

Yes. The Generell produktinformation section includes a component layout with 18 labeled items, and section M4 (Tekniska service data) contains wiring schematics for the 24V system, including the controller connections. You’ll also find fuse locations and the safety pedal circuit.

What torque values are listed for the drive motor mounting bolts?

Page 26 in the original file. Values are in Nm.

Is the manual in English or Swedish?

The manual is primarily Swedish, but the illustrations, tables, part numbers, and torque specs are machine-readable. That’s fine for any mechanic who reads torque wrenches and wiring diagrams. The section headers also include English translations in parentheses, e.g., “Generell produktinformation (General product information)”.

How do I know which T-code my truck belongs to?

Check the machine number plate on the chassis. The manual lists T-code 374 for SPS1.35, 375 for SPS1.6, 376 for SPS1.35L, and 377 for SPS1.6L. Match your serial number range (e.g., 289337AA-) to the corresponding section. The document index page 3 breaks it down clearly.

If you run a shop that sees these BT units — and warehouses in San Antonio, Houston, and Dallas have plenty of them — you need the real manual. The aftermarket junk costs you time and parts. Access the Factory Manual now, print section M4, and keep it in a page protector on your toolbox. Your wallet and your spine will thank you.