The counterweight is one of the most critical safety and performance components on any Clark forklift. Positioned at the rear of the truck, this solid cast-iron mass offsets the weight of the load carried on the front forks, preventing forward tipping during lifting, travel, and braking operations. Understanding its function, specifications, and proper handling procedures is essential for safe and efficient forklift operation.
Function and Design
The counterweight serves as the primary balancing mechanism for the forklift. When a load is placed on the forks at the front of the truck, the counterweight at the rear provides the necessary opposing force to maintain stability. The weight must be great enough to counteract forward tipping when lifting or stopping with a capacity load.
On electric Clark forklifts, the battery also contributes significantly to the counterweight. The minimum battery weight for each truck is stamped on the nameplate, and the truck should never be operated with a battery that weighs less than the specified minimum.
Clark uses different counterweights based on truck capacity and battery compartment length. The counterweight is secured to the frame by large, hardened steel bolts. These bolts are made of special high-tensile steel and are not commercially available—they must be replaced only with genuine Clark replacement parts when necessary.
Counterweight Specifications by Model
Counterweight weights vary significantly across Clark’s product range. Below are specifications for representative models:
GEX Series (Electric)
The GEX series uses different counterweights depending on wheelbase and capacity configuration:
Configuration Counterweight Weight
Short wheel base 560 kg (1,235 lbs) / 760 kg (1,675 lbs) / 720 kg (1,587 lbs)
GEX 50 (10,000 lb Capacity)
The Clark GEX 50 is a solid-pneumatic electric counterbalance forklift with an operating weight of 17,439 lbs.
C500 Series
The Clark C500-25P (1980 model) typically weighs around 5,000 to 5,500 lbs total. For transport, the exact weight should be verified on the data plate. The Clark C500 Y130 D has a total weight of 8,000 kg.
C80D900 (8-Ton Diesel)
The C80D900 features a counterweight that has been made 500 kg heavier than standard, making it ideal for tough outdoor use in construction, building materials, wood processing, metalworking, paper and beverage industries, and logistics.
Counterweight Bolt Torque Specifications
Proper torque on counterweight mounting bolts is critical for safety. The bolts must be tightened to the manufacturer’s specified torque values:
Fastener Torque Specification
Counterweight Mounting Bolts (GEX) 340–380 N·m (251–280 lb·ft)
Counterweight Bolt (General) 175–225 lb·ft
Counterweight Extension Bolts 375–425 lb·ft
Counterweight to Spacer Mounting Bolts 375–425 lb·ft
Counterweight Removal Procedure
Removing a Clark forklift counterweight is a high-risk operation that requires proper training, equipment, and safety precautions. The counterweight is only held on by mounting bolts and can fall if not handled correctly, potentially causing severe injury or death.
Before Starting:
Park the truck on a hard, level, and solid surface such as a concrete floor
Position the upright vertically and fully lower the forks or attachment
Place all controls in neutral, turn the key switch OFF, and remove the key
Apply the parking brake and block the wheels
Secure the fork carriage and inner rails with wooden beams and chains if working underneath
Removal Steps (GEX Series Example):
Remove the Electronic Controls cover
Remove the controller from the counterweight
Remove the battery connector from the counterweight
Raise the hood of the operator's seat and remove the battery
Install an eyebolt in the counterweight. The eyebolt should bear 1,193 kg (2,630 lbs)
Using an overhead hoist with sufficient lifting capacity, attach the hoist chain to the eyebolt. Slowly lift the hoist until slack is removed from the chain
Remove the counterweight mounting bolts
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 on the frame
Carefully lower the counterweight onto a sturdy pallet, setting it on its flat side if possible
Critical Safety Requirements:
Hoisting equipment must be capable of handling the weight of the counterweight
Use only overhead lifting equipment with a safe lifting capacity exceeding that of the counterweight
Only trained personnel familiar with correct procedures should remove the counterweight
The counterweight must be maintained in good condition and securely attached to the truck at all times
When removed, store the counterweight at floor level to prevent falling or tipping
Never raise the truck by lifting under the counterweight
Towing and the Counterweight
The counterweight also serves as a towing point for disabled Clark forklifts. When towing is necessary:
Use an approved solid metal tow bar with towing couplers that connect to the towing pin in the counterweight or connect to the frame/chassis through the counterweight
Check that the counterweight bolts are in place and properly torqued before towing
Obtain another lift truck of equal or larger size for towing, preferably partially loaded for traction
Ground Clearance Considerations
The counterweight affects the forklift's ground clearance. On some Clark models, ground clearance under the counterweight is approximately 3 inches. This should be considered when operating on uneven surfaces or ramps.
Warranty Coverage
Clark offers warranty coverage on certain models that includes the counterweight. The TWO-YEAR/4000 HOUR PROTECTION covers the TMX250, ECX360, and GEX230 models when purchased or leased from Clark or an authorized Clark dealer.
Summary
The Clark forklift counterweight is a solid cast-iron component mounted at the rear of the truck that provides essential balance for safe load handling. Counterweight weights range from approximately 560 kg (1,235 lbs) on smaller GEX models to over 8,000 kg on heavy-duty C500 and C80D900 units. The counterweight is secured by special high-tensile steel bolts that must be torqued to 340–380 N·m (251–280 lb·ft) on GEX models, with other models requiring 175–425 lb·ft depending on the specific fastener. Removal requires a crane or hoist with adequate capacity, proper eyebolt installation (minimum 1,193 kg / 2,630 lbs rating), and trained personnel. Counterweight bolts must only be replaced with genuine Clark parts, as they are not commercially available. The counterweight also serves as a towing point and contributes to ground clearance specifications. Always consult the specific service manual for your Clark model before performing any work on the counterweight.