How to repair broken-off forks on fork lift trucks
Sometimes forks break due to heavy loads. As these forks are made of hardened and tempered alloy steel, we recommend our 30 rods for this repair. (Our 30 has no carbon migration and high physical properties)
1. Double bevel the mating edges of the broken part to 80 or 90 degree bevel. (*Grind the bevel to avoid contaminating the base metal, and be sure to leave a 1.5 mm gap between the two parts to insure a complete weld*)
2. Do not dismantle the broken fork from the trunk hoist. Instead, lower the hoist and mate up the hoist hook section with the tines. To maintain alignment, use blocks.
3. Tack weld, using our 30 rod. (*No preheat is necessary, unless the base metal is very cold)
4. Weld using 1/8" rod for the first pass for good penetration, then follow with the 5/32" or 3/16" rod. Use stringer beads. Peen each pass, clean slag, and wire brush between passes. Back-whip to fill the crater left between passes. Pause and let the metal cool if it starts to redden--perhaps working on another fork while one cools.
5. Take the fork from the truck hoist after the grooves are filled, and weld flush the other half of the bevel.
6. Turn forks over and change position to begin flat welding. In the corners, build a reinforcement of weld metal about 1/3 the thickness of the fork.
7. Lay the fork on one side and then the other, applying stringer beads to cap the ends of the bevel. (*This eliminates crack starters and notches at the weld ends*)
8. Cool and touch up rough areas with a grinder.
