Occupational Safety Instruction No. 12 for Forklift Operation

13 March 2026

APPROVED:

Director’s Order

______________________

dated «__» ___________ 20__ №

OCCUPATIONAL SAFETY INSTRUCTION
No. 12
for Forklift Operation

General Provisions

1.1. This Instruction has been developed in accordance with NPAOP 0.00-4.15-98 “Regulation on the Development of Occupational Safety Instructions” and NPAOP 0.00-6.03-93 “Procedure for the Development and Approval by the Employer of Occupational Safety Regulatory Acts Applicable at the Enterprise.”

1.2. This Instruction applies to all employees who operate forklifts used at (company name) “____________” (hereinafter — the Company).

1.3. Forklift operation is permitted for employees (hereinafter — operators) who are at least 18 years old and who:

have the appropriate qualification and a certificate/license to operate the relevant type of forklift;
have passed a medical examination and have no contraindications;
have completed the required special occupational safety training;
have completed induction and initial occupational safety briefings.

1.4. Employees must undergo refresher occupational safety briefings once every three months.

1.5. Once a year, employees must complete special training and a knowledge test on the relevant occupational safety regulations.

1.6. While performing their job duties, each employee must:

perform only the work specified in their job/work instruction or assigned by their supervisor;
comply with internal labor rules;
know the forklift design, the operating principles of its units and mechanisms, and its technical specifications;
take care of their own safety and health, as well as the safety and health of others while performing any work or while on the Company’s premises;
know and comply with fire safety rules, know the locations of primary firefighting equipment, and be able to use it;
know and comply with occupational safety regulations and sanitary-hygienic rules, and be able to provide first aid;
use the provided collective and personal protective equipment.

1.7. Smoking and eating are permitted only in designated areas.

1.8. The main hazards which, under certain circumstances, may lead to injury or occupational disease include:

injury hazard from moving or rotating parts of equipment;
entanglement hazard (hair, clothing, personal protective equipment, etc.) in moving machine parts;
hazard of objects falling from height onto the employee;
respiratory hazards from dust particles;
lung damage hazard from inhaling harmful or hazardous chemical vapors or gases;
burn hazard due to contact with high-temperature surfaces;
hazard from increased noise levels;
fire hazard;
vehicle striking a person;
falling from a vehicle;
vehicle rollover hazard due to improper load placement/securement or overloading;
load fall hazard due to improper securement or transportation;
hazards caused by poor technical condition of the vehicle;
physical overexertion due to awkward working posture.

1.9. The employee is provided free of charge with special clothing, special footwear, and other personal protective equipment (PPE) in accordance with applicable industry standard norms or the norms specified in the Collective Agreement.

1.10. The operator’s workplace includes warehouse and service premises, as well as the forklift cabin.

1.11. Forklifts shall comply with the requirements set out in Appendix 1.

1.12. Forklifts of all types, except manually propelled stackers, must be registered in accordance with the procedure established by the legislation of Ukraine and must have a registration certificate and license plate. Operation of unregistered forklifts is prohibited.

1.13. Forklifts must be kept in proper technical condition by organizing appropriate maintenance and repair.

1.14. Forklifts in operation must undergo periodic technical inspection (check) annually.

1.15. The area intended for loading and unloading operations must be cleared of foreign objects, leveled, illuminated, and have a sufficiently hard surface designed to accept loads.

1.16. Movement of forklifts within the enterprise territory must be carried out in accordance with the established traffic scheme for vehicles and employees. The scheme must indicate permitted and prohibited directions, turns, stops, entrances and exits, etc. The scheme must be communicated to all employees and posted near the entrance to the enterprise territory.

1.17. No other handling operations shall be performed in the forklift working zone, and routes for manual carrying and transporting of loads shall not pass through this zone.

1.18. Lighting in the forklift working zone must be sufficiently bright. Forklifts must be equipped with additional lighting if the illumination of the work area is below 32 lux.

1.19. Forklift travel routes must be clear to provide adequate visibility and ease of turning; they must not have significant descents/ascents or low ceilings. Routes must be clearly bounded or marked. If pedestrian movement along the routes is possible, the route width must be increased accordingly.

1.20. The maximum longitudinal slope of a route on which forklifts are allowed to transport loads must not exceed the tilt angle of the forklift mast frame. The route must have smooth transitions at the base and at the top to prevent impacts directed at the load or damaging the forklift chassis. Where there are ascents with a gradient exceeding 10%, warning signs shall be installed on permanent routes. Hazardous areas, including those with height restrictions, must be clearly marked.

1.21. An employee has the right to refuse to perform work if the working conditions pose a threat to their health or life or contradict occupational safety regulatory requirements.

1.22. For violating the requirements of this Instruction, the employee bears administrative, disciplinary, and criminal liability in accordance with the current legislation of Ukraine.

Safety requirements before starting work

2.1. Before starting work, the employee must:

put on and properly adjust the required workwear, safety footwear, and PPE;
receive a task from the immediate supervisor;
familiarize themselves with the work technology and scope, the terrain and features of the site where work will be performed;
inspect the forklift and check its technical condition.

2.2. During the forklift inspection, check its technical condition, paying attention to the serviceability of the braking system, power-assisted steering, engine, transmission, hydraulic system (for leaks in cylinders and hoses), lighting and signaling devices, correct installation of the rear-view mirror, tire pressure; ensure the correct adjustment of the mast carriage lifting and tilt mechanisms. The pre-start forklift inspection checklist is provided in Appendix 1.

2.3. Operation of the forklift is prohibited if the following damages or malfunctions are present:

cracks and deformations in the forklift chassis frame, mast frames, carriage, and forks;
one of the bolts on the bracket fastening the mast frame to the chassis frame is missing;
the locking screw or locknut securing the pin connecting the tilt hydraulic cylinder rod to the mast frame is missing;
leakage of working fluid from the forklift hydraulic system;
presence of air in the hydraulic system;
working fluid pressure in the hydraulic system drops below the norm;
service brake does not provide effective braking or uniform braking of the wheels on one axle;
leakage in the pneumatic brake system causing air pressure in the pneumatic system (with the forklift engine not running) to drop by more than 0.1 MPa per hour;
the pneumatic brake system pressure gauge does not work;
the compressor does not provide the specified air pressure in the pneumatic brake system;
leakage of working fluid from the hydraulic brake system;
parking brake does not hold the forklift, regardless of load, on the maximum slope specified by the manufacturer in the operating documentation for 5 minutes;
steering wheel free play exceeds 20° from the steering wheel position corresponding to straight travel (for rough-terrain forklifts, free play must not exceed 25°);
unsecured, unpinned, disconnected, or damaged steering components;
faulty power steering unit;
wheel is not securely fastened to the hub;
tire tread depth is below the minimum required by applicable legislation;
tire has a through damage or broken cord plies;
gears do not disengage or disengage spontaneously;
propeller shaft is damaged or вибrates;
malfunction or absence of external lighting devices required by the manufacturer;
rear-view mirror is missing;
audible warning signal is faulty;
cab door locks are faulty;
cab air heater is faulty in winter;
absence of a certificate confirming mandatory technical inspection.

2.4. If a hazard to safe work is identified, report it to the immediate supervisor and do not start work. Work may begin only after the identified deficiencies have been eliminated.

Safety requirements during operation

3.1. Stay alert; do not distract yourself or other employees; continuously maintain cleanliness and order at the workplace; keep all forklift units and mechanisms clean and in proper working condition.

3.2. Using two or more forklifts together to handle loads whose mass exceeds the capacity of a single forklift, or to handle oversized loads, is a hazardous operation requiring special safety measures. Such work may be performed only under the direct supervision of the person responsible for the safe performance of forklift operations, or another specially appointed employee, in accordance with process sheets or work execution plans (WEP/PPR). These documents must include rigging and load movement diagrams with the sequence of operations and other instructions for safe lifting and moving. In such cases, drivers must be instructed and practical training must be conducted. After the training, replacement of drivers is not permitted.

3.3. Drivers, maintenance, and repair personnel must not make any additions or modifications to the forklift design that could affect safe operation. Removing the counterweight is prohibited, even if it interferes with work in narrow areas, as it also creates additional load on levers and steering.

3.4. Lifting employees on forklifts that do not have a work platform specifically designed for that purpose is prohibited. Transporting employees on a forklift work platform is not permitted.

3.5. During work, pay special attention to people in the forklift working zone, stationary objects, or objects moving nearby, and ensure the safety of everyone around at all times.

3.6. Do not allow anyone to stand or pass under the forklift’s raised load-handling device, regardless of whether it is carrying a load.

3.7. Use forklifts only for their intended purpose.

3.8. Only loads whose mass corresponds to the forklift’s rated capacity may be lifted and stacked, or, when using an interchangeable attachment, to the combined rated capacity of the forklift and the attachment. Installing any additional means to increase capacity (e.g., additional counterweight or placing people on the forklift) is prohibited.

3.9. During work, pay particular attention to load handling: proper positioning and transportation of the load.

3.10. Only securely arranged, stable, and safe-to-move loads may be transported. Extra caution must be used when transporting excessively long or excessively tall loads.

3.11. When transporting loads whose center of gravity is difficult to determine, operate at the minimum speed and with caution, keeping the load as low as possible (do not raise it).

3.12. When using forks to lift and transport loads, comply with the following rules:

set the fork spacing according to the width of the load being handled;
insert the forks under the load as deeply as possible and ensure that objects behind the load are not damaged by the fork tips. The load must be pressed against the fork backrest and positioned so that no tipping moment occurs; the load must not extend forward beyond the forks by more than 1/3 of the fork length. Then raise the forks to a height sufficient for transport, as specified in the operating manual;
tilt the mast back only as much as needed to stabilize the load; use extra caution with tall or individual items;
transport loads only when the forklift mast is fully tilted back;
to place the load down, lower it slowly; when the load is stable, slightly tilt the mast forward and back the forklift or forks to withdraw the forks from under the load;
oversized loads may be stacked above the overhead guard, but not more than one tier. Moving oversized loads must be performed under the direct supervision of the person responsible for safe forklift operations.

3.13. When stacking loads, comply with the following rules:

approach the stack slowly with the mast tilted back enough to stabilize the load;
after completing this maneuver, when the forklift is positioned directly in front of the stack, set the mast to the vertical position. It is advisable to lift the load slightly above the stack. Then move the forklift forward or, if the forklift has a reach mast/retractable forks, extend them and place the load by lowering the forks;
when braking a forklift with a raised attachment (with or without a load), brake smoothly and carefully;
ensure the load is placed in a stable position in the stack;
then withdraw the forks, lower them to the transport position, and after confirming the path is clear, the driver may begin reversing;
when unstacking, approach the stack and stop so that the fork tips are at least 0.3 m from the stack;
set the fork spacing according to the width of the load. Do not move the load without verifying that the load mass matches the forklift rated capacity;
raise the forks vertically to a position that allows insertion under the load;
insert the forks under the load as deeply as possible while ensuring objects behind the load are not damaged. Then raise the forks enough to take the load;
then raise the forks further until the load is fully separated from the stack; if fork tilt is available, tilt back enough to stabilize the load, or if using a reach mast/retractable forks, retract them;
after confirming the path is clear, the load may be removed from the stack;
lower the load to the transport position and fully tilt back; after ensuring the path is clear, reverse.

3.14. Safety requirements when working inside a box truck (van body):

before entering, make sure the truck is secured with the parking brake and wheel chocks are placed to prevent unintended movement;
before starting work, make sure the floor of the box truck (trailer) can withstand the load from the forklift, the load, and the operator. Inspect the floor for rotten boards, holes, and other damage.

3.15. When driving the forklift around the site, follow the travel route defined in the traffic scheme. Continuously monitor movement, watch pedestrians and vehicles, and keep a safe distance. Observe speed limits in the forklift work area and maintain a safe distance from any vehicle ahead.

3.16. Avoid sudden acceleration and braking, and high-speed turns. Do not start moving with the steered wheels fully turned, except when required in special conditions.

3.17. Interchangeable attachments and the load must be lowered during travel and, if possible, tilted back. Raise the load only for stacking; an exception applies to forklifts specifically designed to travel with a raised load.

3.18. If the load blocks forward visibility, drive the forklift in reverse.

3.19. In exceptional cases (e.g., stacking or entering certain slopes) when it is necessary to travel with the load in front in the direction of travel, operate carefully. Use auxiliary means or assign an escort worker(s) to guide and signal. In this case, the longitudinal slope during transport must not exceed the forklift mast tilt angle.

3.20. Reduce speed and sound the horn at intersections and in other locations with limited visibility.

3.21. When maneuvering with a raised load, use steering and braking controls smoothly.

3.22. Do not overtake other vehicles (forklifts, trucks, etc.) moving in the same direction at intersections, in limited-visibility areas, or in hazardous places.

3.23. Avoid striking obstacles that may damage the forklift or cause injury.

3.24. It is prohibited to place hands, feet, or head between mast uprights or between forklift parts that may move relative to each other.

3.25. During travel, do not lean outside the forklift’s outline.

3.26. If people or other vehicles are nearby, sound the horn before turning.

3.27. Long loads may be transported only in open areas with level surfaces. The load-gripping method must prevent the load from collapsing or falling sideways. The load must be securely packaged in advance.

3.28. Maximum forklift speed must not exceed:

10 km/h — on the enterprise territory;
5 km/h — inside production and other premises;
3 km/h — on turns, when entering/leaving gates, when emerging from behind a building corner, in areas with heavy pedestrian traffic, and when reversing.

The driver must select the speed based on traffic intensity, presence of employees/third parties in the work zone, distance, visibility, road surface condition, route width/profile, forklift type, and the transported load, etc. Use special caution on dirty and slippery roads.
In all cases, operate at a speed that allows the forklift to stop safely.

3.29. When driving and operating on slopes, comply with the following:

ascend/descend slowly;
without a load, travel with the mast lowered and tilted back;
do not turn on a slope or cross it at an angle;
maneuver near the edge of a slope or inclined platform with caution; keep at least one wheel-width away from the edge;
when ascending/descending slopes steeper than 10%, the loaded forklift should (where possible) move so that the load faces uphill;
on slopes, travel with the load and attachments tilted back (where possible) and raised enough to avoid contact with the road surface and obstacles.

3.30. When traveling under elevated installations (lights, pipelines, fire protection devices, etc.), ensure there is adequate clearance between them and the forklift or the load.

3.31. Before passing through narrow aisles/doors, between stacks, equipment, or building structures, make sure there is sufficient clearance for the forklift, operator, and load, and ensure no employees or third parties are in the work zone.

3.32. When parking, put the forklift into a non-operating state: fully lower the mast, set controls to neutral, switch off the power source, apply the parking brake, and take measures to prevent accidental/unauthorized movement.
Do not block access to fire exits, stairs, or fire protection equipment when parked.

3.33. During loading/unloading and transport operations, the forklift operator must:

before moving, ensure the route is clear of people and give a warning horn signal;
not lift or carry loads exceeding rated capacity; allowable load on the forks (depending on load center and lift height) must be shown on the capacity chart plate;
lift and tilt the mast with the load carefully, without jerks, only when the mast is vertical or tilted back; gradually increase engine speed and move hydraulic control levers smoothly;
use extra caution when tilting a raised load; avoid sudden lever movements and sudden braking, which can cause tipping or load falling (especially at height);
brake the forklift when lifting/lowering after carefully checking the pick-up/set-down area;
avoid sharp turns while transporting; do not raise/lower the load while moving;
begin travel with a load only when the load is raised to the height specified in the operating manual and the mast is fully tilted back;
transport and stack containers one unit at a time;
transport only when the load is tight against the fork backrest and evenly distributed on the forks;
do not transport loads with a load center farther than specified on the capacity chart;
do not approach loading/unloading points at high speed and do not brake sharply, especially on wet/slippery surfaces and ice;
use caution in narrow aisles; do not hit stacked loads during turns;
work at night only with sufficient lighting of stacks and loading areas;
transport small piece goods only in special containers, not loaded above the container sides;
do not allow people under the load;
if partial loss of stability occurs (rear wheels begin lifting), immediately lower the load;
stop operating if suspicious noises/cracking/grinding or other unusual signs appear in hydraulics, controls, or other units;
do not leave the forklift unattended with the engine running and do not leave the operator position when the load/attachment is raised;
do not drag loads; do not lift/transport poorly placed loads;
observe stacking limits for containers; do not stack defective containers and do not push/pull loads in a stack;
do not work in cluttered areas or on icy/slippery, unsanded and uncleared surfaces; do not lift loads covered with soil/debris/snow, frozen, jammed, or embedded in concrete;
do not lift/lower a load near a wall/column/stack/railcar/vehicle/machine if people are between the load and those objects;
do not tip/rotate loads without a special tipper attached to the forklift carriage;
do not insert forks under a load if clearance is insufficient and do not lift with only one fork, except as allowed by process sheets;
do not set loads down on gas/steam pipes, electrical cables, or temporary floors;
do not stand on forks or other attachments until they are fully lowered to the ground;
do not transport flammable liquids or acids if the battery is located near the mast; handling and transport of explosive cargo must comply with applicable law;
do not lift small piece goods on pallets above the protective guard that shields the operator area from falling loads;
multi-forklift loading/unloading is allowed only with a process sheet or work execution plan; the load on each forklift must not exceed its rated capacity.

3.34. Preventive maintenance or repair of the forklift with raised attachments is prohibited unless safety supports/devices are used.

3.35. If the operator must leave the forklift temporarily (e.g., lunch break), they must park it outside traffic and loading/unloading zones, take the control-circuit key with them, apply the parking brake, and place wheel chocks even on a slight slope. Leaving the forklift on road slopes, near warehouse doors, or with the mast carriage raised and a load on the forks is prohibited.

3.38. Prohibited:

allowing persons not appointed by the work supervisor to sling/tie loads;
lifting loads in an unstable position or in defective containers;
lifting loads of unknown weight or exceeding rated capacity;
sudden acceleration/braking and high-speed turns;
lifting bundled loads without devices preventing items from falling;
lowering loads onto electrical cables, gas/steam pipelines, or temporary floors;
loading/transporting compressed gas cylinders, acids in glass containers, and other hazardous substances;
standing on a lifted load, carrying people, or lifting people with the mast;
freeing loads buried in soil/snow, structures/equipment bolted down or embedded in concrete using the forklift working attachment;
leaving the forklift with the engine running;
refueling with the engine running;
leaving the cab with a raised load/attachment;
placing a load by crane directly onto the forklift forks;
being under a raised load.

3.39. Safety requirements when working with a battery charger:
a) charger requirements:

the charger and cables must not be damaged. Terminals must be factory-made. Connecting cables to the battery by throwing/clamping or twisting is prohibited;
batteries set for charging must be connected only with conductors fitted with lugs that fit tightly on the battery terminals and prevent sparking. Connecting battery lugs by “twisting wire” is prohibited. Connecting/disconnecting batteries to/from the charger must be done only when the charger is switched off;
charging current connectors must be designed so that during charging the battery is disconnected from the forklift’s operating circuits.

b) Safety requirements when charging batteries:

battery charging must be performed only with the caps open and the supply-and-exhaust ventilation switched on;
do not allow the battery terminals to be shorted with metal objects;
avoid touching two battery terminals simultaneously to prevent short circuits and sparking;
monitor the charging process using measuring instruments (voltmeter, hydrometer, etc.);
check battery voltage only with a dedicated instrument (voltmeter, multimeter, etc.);
connect the battery terminals for charging and disconnect them after charging only when the charger is switched off;
connect batteries using lead-plated terminals that ensure a tight contact and prevent sparking.

c) Prohibited:

leaving charging batteries unattended;
using a faulty charger or damaged cables;
pulling the cable to disconnect the charger from the power supply; stretching, twisting, bending the cable; placing objects on the cable; allowing the cable to contact hot surfaces;
disassembling or repairing batteries or the charger.

3.40. Immediately report to the immediate supervisor any deficiencies that create danger for others and cannot be eliminated personally, as well as all accidents and emergencies that occurred during work.

Safety requirements after finishing work

4.1. After finishing work, the forklift operator must:

inspect the forklift (chassis frame, mast frame, carriage, forks, wheels) and ensure there are no cracks, dents, or other deformations, and no leakage of working fluid from the load-lift hydraulic cylinder and mast-tilt hydraulic cylinders;
park the forklift in the designated parking area;
switch off the ignition (disconnect the battery);
clean the forklift from dirt and ensure there are no leaks of oil, brake fluid, or coolant. If a leak is found, eliminate it immediately;
inform the person responsible for the technical condition of forklifts about any malfunctions and damage detected during operation.

4.2. Remove special clothing, safety footwear, and other PPE and place them in the storage area.

4.3. Wash hands and face; take a shower if necessary; change into clean clothes.

4.4. Report to the supervisor any deficiencies identified during work.

Safety requirements in emergency situations

5.1. The following emergencies may occur during work:

damage to electrical insulation, resulting in touch voltage and step voltage;
ignition of equipment and fire;
load fall;
forklift overturning;
road traffic incidents (accidents).

5.2. In case of an emergency, it is necessary to:

cordon off the hazardous area and prevent unauthorized persons from entering; if the situation does not threaten the life and health of employees and will not lead to more severe consequences, preserve it as it was at the moment of the event for investigation;
in case of fire, start extinguishing it; if it cannot be extinguished by your own efforts, call the fire service;
report the incident to the work supervisor.

5.3. In case of an accident (injury):

immediately free the injured person from the harmful factor;
move them to a safe place;
assess the injured person’s condition; provide first aid if needed, and in severe cases call emergency medical assistance.

5.4. When dealing with an emergency, follow the instructions of the work supervisor.

DEVELOPED BY:

Head of Production _____________________ Full Name
(signature)

APPENDIX 1

Forklift Requirements

Forklifts shall be able to overcome, with the rated load, the slope specified by the manufacturer in the operating documentation.
Forklifts shall be equipped with towing devices (hook, eye, etc.). If the forklift is intended to be used as a tractor, the design of the towing/coupling device shall prevent accidental uncoupling.
Forklifts with pneumatic tires shall have the required tire pressure indicated on the body.
Forklift wheels protruding beyond the outer contour of the chassis shall be protected to minimize the risk of injury to the operator in the normal working position from objects thrown up by the wheels.
The design of forklift systems shall prevent dripping of hydraulic working fluid, fuel, or harmful liquids (in the event of loss of tightness), especially onto hot components that could ignite such liquids. Dripping into designated closed or filling containers is permitted.
Forklifts shall ensure longitudinal and lateral stability with and without a load during stacking and traveling.
A location for mounting a fire extinguisher shall be provided on the forklift.
Forklift metal structures and metal parts shall be protected against corrosion according to operating conditions.
In a place clearly visible to the operator, capacity charts shall be attached showing:
- changes in load capacity depending on the load center position;
- changes in load capacity depending on the lifting height.
Braking system requirements:

forklifts shall be equipped with two independent systems to actuate the service brake and the parking brake;
the parking brake shall be actuated manually or automatically and remain applied until intentionally released;
actuation of the service brake shall not automatically cause simultaneous actuation of the parking brake;
the service brake system shall ensure effective braking by a single press of the pedal or other actuating element;
a pneumatic brake system using stored energy shall be equipped with a warning device that activates when the stored energy level falls below 50% of the manufacturer’s specified maximum. The warning device shall be installed in a clearly visible place. The operator must hear the warning signal, which shall be continuous;
the holding effectiveness of the forklift by the parking and service brake systems shall be checked in accordance with the operating documentation;
the forklift skidding angle during service braking shall not exceed 8°.

Mast requirements:
a) the maximum lifting height of the forks and lowering to the lowest position shall be limited by the lift hydraulic cylinder or a special device;
b) the limit tilt angles of the forks forward and backward shall be limited by tilt cylinders or a special device. Devices performing side shift, extension, rotation, and other work operations shall have travel limiters;
c) forklift forks shall have clear markings including:

manufacturer’s trademark (or name);
rated fork capacity in kilograms;
rated load center distance from the front face of the fork backrest in millimeters;
month and year of manufacture, serial number;
d) forks shall be fitted with devices for transverse locking on the fork carriage;
e) the forklift design may allow installing other interchangeable attachments instead of forks;
f) chains used on forklifts shall comply with applicable legal requirements;
g) fork lifting and lowering speed shall be adjustable and selected by the operator depending on working conditions;
h) a rated load lifted to any height shall be held at that height. Unintentional lowering within the first 10 minutes shall not exceed 50 mm with the mast in the vertical position;
k) mast tilt speed shall be adjustable and selected by the operator depending on working conditions;
l) the unintentional forward tilt angle of the mast with the rated load shall not exceed 5° within 10 minutes with the mast vertical and the rated load lifted to 2500 mm; for low-lift forklifts — at the maximum lifting height.

Hydraulic equipment requirements:

hydraulic system components (hydraulic devices, hoses, pipelines, connections, etc.) shall be leak-tight. Hoses, pipelines, and connection elements shall have no visible defects or damage;
forklifts shall be equipped with a safety relief valve in the hydraulic system or another device preventing overload of the lifting mechanism. The safety valve shall be sealed.

Electrical equipment requirements
a) Forklifts with a travel speed above 10 km/h shall be equipped with light-signaling devices to ensure safe operation, including:

a braking signal (brake light);
headlights (one or more);
turn indicators;
clearance/position lights.

b) Forklifts shall be equipped with an audible warning device that operates independently of the device that switches off the control circuit. The warning sound must be clearly audible.
c) Forklifts shall be equipped with key-operated devices (a key/tag key) or another device by which the control circuits can be switched on or off.
d) The electrical circuit shall provide a plug connection for charging the battery and disconnecting it from the rest of the forklift’s electrical components.
e) The electrical circuit shall include electrical protection devices; at fuse locations, the rated current values of the fuses must be indicated.
f) Electrical circuit connections shall be made using a two-wire scheme. Wire insulation shall be resistant to electrolyte and oils. All wires must have clear and durable markings according to the electrical diagram.
g) Electrical conductors shall have terminals/lugs. It is permissible to connect control, lighting, and signaling wires with a cross-section up to 2.5 mm² without lugs.
i) Wires passing through openings in metal structures shall be protected against mechanical damage.
k) Insulation of live parts of electrical equipment shall withstand, for 1 minute, an AC test voltage (25–100 Hz):

500 V — for nominal circuit voltage up to 48 V (DC);
1000 V — for nominal circuit voltage above 48 V (DC).

During testing, the battery, electronic control unit, and signaling/lighting circuits must be disconnected.
During repeat testing, the AC test voltage value is reduced by 20%.
The voltage application time may be reduced to 1 s provided the test voltage is increased by 25%.

l) Insulation resistance of live parts of electrical equipment relative to the forklift frame (cold condition, battery disconnected) shall be at least 0.5 MΩ and shall be checked at least once every 12 months.
Operator workplace requirements

ergonomic requirements for the operator workplace and forklift controls shall comply with applicable legislation;
the workplace of a seated or standing operator shall be arranged so that the operator remains within the forklift outline in plan view while in the normal operating position, except for stackers designed for control from an operator platform (folding/rotating) or from the floor while walking alongside;
the floor of the workplace, footrests, and steps shall have a non-slip surface;
forklifts shall be equipped with access means — steps and ladders with handrails/handles. Structural elements of the forklift may be used as handrails and intermediate steps;
handles and contact surfaces of controls shall be made of corrosion-resistant, non-toxic materials with low thermal conductivity;
a seated operator workplace shall be equipped with an operator seat;
if necessary (e.g., for an accompanying person), a second seat may be provided;
the seated operator workplace may be arranged in a cab;
cabs shall be equipped with a door with a key-lock;
if a closed cab has heating, the heater shall ensure even distribution of warm air; a protective shield/screen shall be provided to protect the operator from burns;
cab ventilation devices shall be provided (fan, etc.);
if cab windows are glazed, safety glass shall be used; the front and rear windows shall be equipped with wipers;
from the operator workplace, with the mast vertical, visibility of the end of one fork shall be ensured in the extreme upper and lower positions, and at a fork lift height of 1200 mm;
the operator cab shall be equipped with a rear-view mirror, a sun-shield device (visor, blind, etc.), a glazed roof window, and design elements enabling natural ventilation with the doors closed;
an operator platform extending beyond the workplace shall be designed to withstand a longitudinal force corresponding to the mass of a loaded forklift applied along the longitudinal axis. The platform shall include reinforcing structural elements and all parts involved in resisting deformation from the longitudinal force;
the surface of a standing-operator platform shall be rigid and have raised edges or a protective rim at least 25 mm high to prevent the operator’s foot from slipping;
a work platform intended for lifting personnel (e.g., for maintenance/repair) shall be equipped with means for fastening and secure fixation to the mast (to the carriage and/or forks), as well as means for attaching and securely fixing workers’ safety harnesses. The platform shall have a non-slip floor, be fitted with guardrails, a toe board at least 100 mm high on all sides, and protection from moving parts of the forklift that may pose a hazard;
materials used for cab/operator workplace finishing (walls, floor, control panels, controls, seat, etc.) shall comply with applicable legal requirements.

Requirements for wheel-steering controls

the forklift steering controls shall be located within the forklift outline in plan view and protected to prevent operator injury;
on forklifts where the operator faces the direction of travel and controls the vehicle using a steering wheel (horizontal, inclined, or vertical), clockwise rotation of the steering wheel while moving forward shall turn the forklift to the right;
when moving forward, clockwise steering wheel rotation shall correspond to turning the forklift right;
steering wheel free play shall not exceed 20°. For rough-terrain forklifts, steering wheel free play shall be no more than 25°;
steering angles, camber and toe angles of the steered wheels, and kingpin inclination angles shall be specified in the forklift operating documentation;
on the tiller of forklifts (electric or manual drive) controlled by an operator walking on the floor, a properly designed handle shall be provided to protect the operator’s hands from injuries caused by doors, walls, columns, etc. Clockwise movement of the tiller corresponds to turning the stacker in the same direction, with the load positioned behind.

Requirements for controls

control lever positions shall be clearly indicated;
on seated-operator forklifts, the travel direction selector lever and the reverse selector lever shall be positioned so that the direction of their movement matches the intended travel direction;
load movement may be controlled using levers, push buttons, handwheels, etc. Load-control levers shall be positioned to be operated by the operator’s right hand and clearly separated from travel controls. Levers shall have clear markings indicating their function. Each symbol shall be placed on the lever itself or on a plate next to it. Each lever, when released, shall automatically return to neutral and the work function shall stop;
push buttons controlling lifting, lowering, tilting, and interchangeable attachments shall return to neutral as soon as they are released. The function of each push button shall be clearly indicated.

Requirements for protective devices
a) Forklifts shall be equipped with the following protective devices:

overhead guard;
load backrest (guard frame) on the mast carriage (if required);
a device preventing overload of the lifting mechanism.

b) On walk-behind forklifts used for high stacking or for handling tall (unstable) or individual loads, a load backrest (guard frame) shall be provided on the mast load plate.
c) Forklifts operated by a seated or standing operator and used for high stacking or for handling tall (unstable) or individual loads shall be equipped with an overhead guard above the operator’s head and a load backrest (guard frame) on the mast load plate.
d) The design and dimensions of the overhead guard shall not restrict the operator’s visibility.
e) If the forklift is equipped with a cab, the cab shall perform the function of the overhead guard.
f) Forklifts shall be designed so that a load backrest (guard frame) can be installed on the mast carriage if needed.
g) Forklifts shall be equipped with an overload prevention device for the lifting mechanism. The overload value at which the device activates shall be specified in the operating manual. The device shall be sealed.
h) A powered mast shall be equipped with devices limiting the lift and lowering height of the load.
Requirements for forklift power systems

above energized battery terminals there shall be an air gap of at least 30 mm, or the battery cover shall have an electrical insulating coating;
ventilation openings shall be provided in the battery compartment above the batteries;
batteries and battery compartments shall be installed to prevent any movement that could injure the operator during normal operation and to limit movement in an аваріy;
charging current connectors shall be designed so that during charging the battery is disconnected from the forklift operating circuits;
an emergency battery disconnect device shall be provided, with convenient and unobstructed access for the operator;
all resistors in the electrical system shall be located to avoid excessive heating and damage.

Requirements for interchangeable load-handling attachments

the design of interchangeable attachments shall ensure safe and secure installation and replacement on the mast carriage;
attachments mounted on forks (e.g., fork extensions, spreader beam, fork-mounted bucket, etc.) shall be equipped with devices (latches) that securely lock them onto the forks;
the attachment shall withstand, without weld seam damage or permanent deformation, a static overload of 25% above rated capacity, and operation with a 10% overload;
pipelines and equipment in assembled form shall be leak-tight at 1.5 times the pressure setting of the relief valve. Testing shall be performed on a special stand after first removing the relief valve;
moving parts protruding beyond the forklift dimensions and potentially hazardous in operation shall have warning paint;
the attachment shall have a plate with a load capacity chart installed.