TH62, TH63, TH82, TH83 and TH103 Telehandlers Machine Systems Caterpillar

Removal Procedure

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Personal injury or death can occur from a counterweight falling during removal or installation. Do not allow personnel under or around the counterweight during removal or installation. Make sure that the lifting device is in good condition and is capable of handling the weight of the counterweight.

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Illustration 1	g00710138
TH82 TH63 TH62

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Illustration 2	g00752585
TH103 TH83

1. Loosen four nuts (1), washers, and the bolts from counterweight (2) but do not remove the bolts, washers and the nuts.

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Illustration 3	g00710145
TH82 TH63 TH62

2. Secure the bracket for the rear lights (an attachment) to the rear of the boom. The weight of the rear lights with the mounting bracket is 26 kg (57 lb).

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Illustration 4	g00710166
Typical example of a TH63

3. Refer to table 1 for the correct weight of the counterweight. Position a lift truck at the rear of the counterweight. Raise the forks in order to support counterweight (2) .

   Note: You must be sure that the weight of counterweight (2) will not exceed the lifting capacity of the lift truck.

4. Carefully remove four nuts (1), washers, and the bolts from the counterweight. Lower the forks and remove counterweight (2) .

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Illustration 5	g00710179

5. Some machines have an additional counterweight. Use steps 1 through 4 to remove counterweight (2). Position the lift truck at the rear of the machine. Raise the forks in order to support counterweight (4) and remove two bolts (3), the washers, and the nuts. Lower the forks and remove the counterweight. Refer to table 1 for the weight of the additional counterweight.

Installation Procedure

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Personal injury or death can occur from a counterweight falling during removal or installation. Do not allow personnel under or around the counterweight during removal or installation. Make sure that the lifting device is in good condition and is capable of handling the weight of the counterweight.

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Illustration 6	g00710179

1. Some machines have an additional counterweight (4) and this counterweight must be installed prior to installing counterweight (2). Use a lift truck in order to position counterweight (4). Refer to table 1 for the weight of the additional counterweight. Raise the forks. Align the bolt holes in the chassis with the bolt holes in counterweight (4) and install two bolts (3), the washers and the nuts. Tighten the bolts to a torque of 460 ± 60 N·m (340 ± 45 lb ft).

   Note: You must be sure that the weight of counterweight (4) will not exceed the lifting capacity of the lift truck.

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Illustration 7	g00710166
Typical example of a TH63

2. Refer to table 1 for the correct weight of the counterweight. Use a lift truck in order to position the counterweight at the rear of the machine.

   Note: You must be sure that the weight of counterweight (2) will not exceed the lifting capacity of the lift truck.

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Illustration 8	g00710145
TH82 TH63 TH62

3. Raise the forks in order to position the counterweight. Install the bracket for the rear lights (an attachment) on the outside of the counterweight. The weight of the rear lights with the mounting bracket is 26 kg (57 lb).

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Illustration 9	g00710138
TH82 Th63 TH62

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Illustration 10	g00752585
TH103 TH83

4. Carefully install four nuts (1), washers, and the bolts. Tighten the bolts to a torque of 460 ± 60 N·m (340 ± 45 lb ft).