Doosan D35C-5 FDA04 Operation & Maintenance Manual page 189

12 Months Inspection
Forks should be inspected, at a minimum, every 12
months. If the truck is being used in a multi-shift or
heavy duty operation, they should be checked
every six months. See "Forks" in the "2000 Service
Hours or Yearly" in "Maintenance Intervals."
Maintenance and Repair
1. Repair forks only in accordance with the
manufacturer's recommendations.
Most repairs or modifications should be done
only by the original manufacturer of the forks or
an expert knowledgeable of the materials,
design, welding and heat treatment process.
2. The following repairs or modifications SHOULD
NOT be attempted.
Flame cutting holes or cutouts in fork blades.

Welding on brackets or new mounting hangers.

Repairing cracks or other damage by welding.

Bending or resetting.

3. The following repairs MAY be performed.
Forks may be sanded or lightly ground, to

remove rust, corrosion or minor defects from the
surfaces.
Heel sections may be ground with a carbon stone

to remove minor surface cracks or defects. Polish
the inside radius of the heel section to increase
the fatigue life of the fork. Always grind or polish
in the direction of the blade and shank length.
Repair or replace the positioning locks on hook

type forks.
Repair or replace most fork retention devices

used with other fork types.
4. A fork should be load tested before being
returned to service on completion of repairs
authorized and done in accordance with the
manufacturer's recommendations.
Most manufacturers and standards require the
repaired fork to be tested with a load 2.5 times
the specified capacity and at the load center
marked on the fork arm.
With the fork restrained in the same manner as
its mounting on the lift truck, apply the test load
twice, gradually and without shock. Maintain the
test for 30 seconds each time.
Check the fork arm before and after the second
application of the test load. It shall not show any
permanent deformation.
Consult the
information as may be applicable to the specific
fork involved.
Testing is not required for repairs to the positioning
lock or the markings.
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Maintenance Section
fork manufacturer for further