Counterweight Replacement
REMOVE
WARNING
The lift truck must be put on blocks for some
types of maintenance and repair. The removal of
the following assemblies will cause large changes
in the center of gravity: mast, drive axle, engine
and transmission, and counterweight. When the
lift truck is put on blocks, put additional blocks in
the following positions to maintain stability:
•
Before removing the mast and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
•
Before removing the counterweight, put
blocks under the mast assembly so the lift
truck cannot fall forward.
The surface must be solid, even, and level when
the lift truck is put on blocks. Make sure that any
blocks used to support the lift truck are solid,
one-piece units. See the Operating Manual or Peri-
odic Maintenance 8000YRM1774.
WARNING
DO NOT operate the lift truck if the capscrew for
the counterweight is not installed. When the cap-
screw is removed, the counterweight can fall from
the lift truck.
WARNING
LPG can cause an explosion. DO NOT cause
sparks or permit flammable material near the LPG
system. LPG fuel systems can be disconnected
indoors only if the lift truck is at least 8 m (26 ft)
from any open flame, motor vehicles, electrical
equipment, or ignition source.
Close the shutoff valve on the LPG tank before
any part of the engine fuel system is disconnec-
ted. Run the engine until the fuel in the system is
used and the engine stops.
If the engine will not run, close the shutoff valve
on the LPG tank. Loosen the fitting on the supply
hose from the LPG tank where it enters the filter
unit. Permit the pressure in the fuel system to de-
crease slowly. Fuel leaving the fitting removes
heat. Use a cloth to protect your hands from the
cold fitting.
NOTE:
The counterweight is held in position on the
frame by two hooks that are part of the frame. One
M24 × 3 × 110 capscrew holds the counterweight to
the lower part of the frame on lift truck models See
Figure 16.
NOTE:
Perform Step 1 for lift trucks equipped with
LPG.
1.
Use the procedures in
Fuel System PSI 2.4L
0900YRM1757 to remove the LPG tank and
bracket so that the counterweight can be re-
moved.
Additional information on the LPG fuel system can
be found in
Fuel System PSI 2.4L
0900YRM1757.
WARNING
The counterweight is heavy. Make sure that the
eyebolts and lifting devices have enough capacity
to lift the weight. The approximate weights of the
counterweight castings are shown in Table 1.
2.
Install washers, lifting eyebolts, and nuts into lift
holes of the counterweight. See Figure 17. Con-
nect a crane to the lifting eyebolts and raise the
crane until it holds part of the weight of the coun-
terweight.
3.
Remove the tow pin from counterweight.
4.
Remove the capscrew from counterweight and
frame. See Figure 16 and Figure 17. Use the
crane to lift the counterweight from the lift truck.
Put counterweight on the floor so that it has stabil-
ity and will not fall over. Take care not to damage
exhaust or cooling system components.
Table 1. Weight of Counterweights
Model
kg
lb
GLC050LX (B967)
1401
3088
GLP/GDP20LX (B974)
950
2094
GLP/GDP25LX (GLP/
GDP050LX) (B974)
1230
2712
GLP/GDP25LX (GLP/
GDP050LX) (B974)
1335
2943
Counterweight Replacement
0100 YRM 1766
16
