Hyster CHALLENGER H135XL, Service & Repair Manual

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Counterweight Repair 100 SRM 322
Counterweight Repair
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:
upright,
drive axle, engine and transmission, and coun-
terweight. When the lift truck is put on blocks,
put additional blocks in the following posi-
tions to maintain stability:
a. Before removing the upright and drive axle,
put blocks under the counterweight so the
lift truck cannot fall backward.
b. Before removing the counterweight, put
blocks under the upright 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.
WARNING
Do not operate the lift truck if the capscrew for
the counterweight is not installed. When the
capscrew is removed, the counterweight can
fall from the lift truck.
1. Remove the grille and the cover for the hydraulic
pump.
2. Remove the bracket for the rear hood mount from
the frame. Put a block between the hood and the
radiator.
WARNING
Make sure any lifting devices have the correct
capacity for the parts being removed.
3. Put a lifting strap through the hole in the coun-
terweight. Connect a lifting device to the strap.
Remove the bolt that holds the counterweight to
the frame. See Figure 2.
4. Lift the counterweight from the frame. Put the
counterweight in a position so it has stability.
INSTALL
1. Connect a strap and lifting device to the coun-
terweight. Lift the counterweight into position
on the frame. Make sure the counterweight is in
position on the mounts.
2. Install the bolt for the counterweight. Install the
cover for the hydraulic pump. Install the grille.
3. Install the bracket for the hood mount. Install
the capscrews for the hood mount. Adjust the
hood as described in the procedures for the hood.
Weight of Counterweights
H6.00XL (H135XL) H7.00XL (H155XL)
2594 to 2654 kg
(5720 to 5852 lb)
3092 to 3162 kg
(6818 to 6972 lb)
Figure 2. Counterweight
2