Removing a forklift counterweight is a high-risk maintenance procedure that requires strict adherence to safety protocols, proper lifting equipment, and manufacturer-specific procedures. The counterweight is a massive cast-iron or steel block weighing hundreds to thousands of pounds, and improper removal can result in severe injury or death. This guide provides a comprehensive overview of the safety requirements, preparation steps, and removal procedures.
Safety Requirements and Preparation
Regulatory Compliance
OSHA regulations under 29 CFR 1910.178(q)(6) prohibit adding extra counterweighting to fork trucks unless approved by the truck manufacturer. This regulation underscores that counterweights are precision-engineered components critical to forklift stability. Any modification or removal must follow manufacturer-approved procedures.
Pre-Removal Safety Checklist
Position the forklift on a hard, level, and solid surface such as a concrete floor, free from obstructions or interference.
Place the upright in vertical position and fully lower the forks or attachment.
Put all controls in neutral, turn the key switch OFF, and remove the key.
Apply the parking brake and block the wheels with chocks or wedges.
Disconnect the battery (for electric trucks) to prevent unintentional starting.
Remove any components that may interfere with counterweight removal, such as:
Electronic controls cover and controller (if mounted on counterweight)
Battery connector
Battery (if required for access)
For LPG models: remove the LPG tank and bracket
Overhead exhaust if installed
Secure the fork carriage and inner rails with wooden beams and chains if working near raised components.
Establish a barricaded work zone to prevent unauthorized personnel from entering the area.
Ensure all workers read and understand the manufacturer-specific instructions before beginning.
Lifting Equipment Requirements
Critical Safety Rule: The counterweight is only held on by mounting bolts and would fall if these were undone without proper support.
Use only overhead lifting equipment with a safe lifting capacity exceeding that of the counterweight
Install an eyebolt in the counterweight lifting hole. The Clark GEX20 requires an eyebolt rated for 1,193 kg (2,630 lbs)
Attach lifting cables or slings of sufficient strength to the lifting eye correctly
Slowly lift the hoist until slack is removed from the chain or sling before removing bolts
Certified cables and shackles of adequate load rating must be used
Note: Using a forklift to remove another forklift's counterweight is not recommended for fixed counterweights due to the risk of damage or misalignment.
Step-by-Step Removal Procedure
1. Assess the Mounting System
Different manufacturers use distinct mounting configurations:
High-tensile steel bolts passing through the rear chassis plate
Hook-and-pin or interlocking designs requiring specific alignment
V-shaped saddles on the top where the weight fits
Some models use a single large retainer bolt; others use multiple bolts
Always consult the specific service manual for your forklift make and model before proceeding.
2. Apply Penetrating Oil
Apply a high-quality penetrating oil to the bolt threads hours before the operation, as fasteners may have been subjected to years of vibration and environmental exposure.
3. Install the Lifting Device
Connect lifting cables, slings, or an eyebolt to the counterweight's lifting point(s)
Attach the hoist chain to the lifting device
Slowly lift the hoist until slack is removed from the chain
4. Remove the Mounting Bolts
Professional Practice: Remove the upper bolts first while leaving the lower bolts slightly threaded to provide a safety buffer. This prevents the counterweight from shifting or pivoting unexpectedly as the final tension is released.
The number and type of bolts vary by model:
Clark GEX20: Counterweight mounting bolts
Still R70-20: Three M24 × 85 bolts securing the counterweight to the frame
Some models: Two bolts (one on each side) securing the counterweight
Hyster: Three capscrews holding the counterweight to the frame
5. Lift and Remove the Counterweight
Stand clear of the counterweight as it is being hoisted, moved, or mounted
Slowly lift the counterweight from the truck frame until it is free from the counterweight hooks
Move the counterweight back to clear the electronic controls or other components
Never allow personnel under or around the counterweight during lifting
Slowly lower the counterweight onto a sturdy pallet
If possible, set the counterweight on its flat side
Installation and Reassembly
Installation is the reverse of removal, with these critical requirements:
Place the counterweight against the mounting hole of the frame using the hoist and lifting device
Use prybars for location adjustments during mounting
Do not place any part of your body between the counterweight and truck
Inspect mounting bolts to ensure they are in good condition before installation
Use only manufacturer-replacement parts
Tighten bolts to the specified torque (see torque specifications below)
Remove the hoist and lifting device
Never allow a truck to be put into service without the counterweight mounting bolts in place
Counterweight Bolt Torque Specifications (2026)
Torque specifications vary by manufacturer and model. Always consult your specific service manual. Below are reference values:
Manufacturer / Model Torque Specification Source
Clark GEX20 340–380 N⋅m (251–280 lb-ft)
Still R70-20 660 Nm
Doosan D20S/D25S 400 ± 60 N⋅m (300 ± 45 lb-ft)
Generic Heavy Equipment 390 ± 40 kg⋅m (280 ± 290 ft⋅lb)
Caterpillar TH103 460 N⋅m (340 lb⋅ft)
Large Excavator 1,910 N⋅m (1,410 lb-ft)
Post-Installation Checks
Check the bolts and torque regularly
Never operate a lift truck or handle loads with the counterweight removed
Verify all electrical connections (tail lights, wiring harnesses) are reconnected
Test the forklift in a controlled environment before returning to service
Summary
Forklift counterweight removal is a high-risk procedure requiring proper safety precautions, manufacturer-specific procedures, and adequate lifting equipment. The counterweight is held only by mounting bolts and must be supported by a crane or hoist before any bolts are removed. Key requirements include positioning on level ground, blocking wheels, using lifting equipment with capacity exceeding the counterweight weight, removing upper bolts first while leaving lower bolts as a safety buffer, and torquing mounting bolts to manufacturer specifications upon reinstallation. Always consult the specific service manual for your forklift make and model, and never operate a forklift without the counterweight properly installed and secured.