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TSG N0001-2017: Special Purpose Motor Vehicles in Defined Fields -- Safety and Technical Supervision Regulation
TSG N0001-2017
TSG
SPECIAL EQUIPMENT SAFETY TECHNICAL SPECIFICATION
Special purpose motor vehicles in defined fields
safety and technical supervision regulation
Issued by. General Administration of Quality Supervision, Inspection and
Quarantine
January 16, 2017
Table of Contents
Foreword ... 4
1 General ... 6
2 Design, manufacture, retrofitting and repair ... 8
3 Safety management of use... 21
4 Inspection ... 24
5 Supplementary provisions ... 28
Appendix A Product certificate of special motor vehicle in defined field ... 30
Appendix aa Forklift product data sheet ... 31
Appendix ab Off-road tourist sightseeing vehicle product data sheet ... 32
Appendix B ... 33
Forklift inspection item list ... 33
Appendix C Off-road tourist sightseeing vehicle inspection item list ... 35
Special purpose motor vehicles in defined fields
safety and technical supervision regulation
1 General
1.1 Purpose
In order to ensure the safe use of special motor vehicles in the defined field,
prevent and reduce accidents, protect people’s lives and property, and promote
economic and social development, this regulation is formulated in accordance
with the “Special Equipment Safety Law of the People's Republic of China” and
the “Regulations for Safety Supervision of Special Equipment”.
1.2 Meaning and scope of application
In accordance with the Special Equipment Catalogue, special motor vehicles in
a defined field (hereinafter referred to as field vehicle) refer to special motor
vehicles that are used only in specific areas such as factories, tourist attractions,
and playgrounds, except for road traffic and agricultural vehicles. It includes
mobile industrial vehicles and off-road tourist sightseeing vehicles.
1.2.1 Mobile industrial vehicles
In this regulation, a motorized industrial vehicle is a forklift. Forklift is a self-
propelled vehicle that lifts the load to a certain height and carries out stacking
operations through a gantry and a fork, it includes a counterweight type forklift,
a reach type forklift, a side forklift, a straddle forklift, a pallet stacker, and three-
way stacker.
Note 1-1. The forklift specified in this regulation does not include a detachable
attachment.
1.2.2 Off-road tourist sightseeing vehicles
Off-road tourist sightseeing vehicles (hereinafter referred to as sightseeing
vehicles) include sightseeing vehicles and sightseeing trains.
Sightseeing vehicles are trackless, non-trolley, non-enclosed, self-propelled
vehicles with 4 or more wheels (including 4), including battery sightseeing
vehicles and internal combustion sightseeing vehicles.
Sightseeing train refers to a trackless, non-trolley, non-enclosed, self-propelled
passenger vehicle that includes 8 or more (including 8), composing one tractor
brake device, and shall be directly operated by the driver;
(7) The number of wheels of the tractor head and each compartment of the
sightseeing train shall be greater than or equal to 4.
2.2 Design
2.2.1 General requirements
(1) There shall be a complete, correct, and uniform design document. The
design document shall include the design mission statement, design
calculation book, design drawings, schedules, use maintenance
instructions, and main parameter tables;
(2) Forklifts shall be left with the location where the license plate is to be
installed. The sightseeing vehicle shall be left with the location for the
installation of the front and rear license plates. The dimensions of this
location shall comply with the requirements of the “Regulations for the
Use of Special Equipment” (TSG 08-2017);
(3) Each compartment of the sightseeing vehicle and sightseeing train shall
be provided with a location for fixing and storing the fire extinguisher, and
it is easy to access;
(4) The lateral stability angle of the sightseeing vehicle under no-load
condition is not less than 35°;
(5) The stability of the forklift shall meet the requirements of the relevant
stability verification test;
(6) Forklifts with explosion-proof functions shall meet the requirements of GB
19854-2005 “General rules of explosion-proof techniques of industrial
trucks for explosive atmospheres”, GB/T 26950.1-2011 “Explosive-proof
industrial trucks - Part 1. Battery-operated industrial trucks”, GB/T
26950.2-2015 “Explosive-proof industrial trucks―Part 2. Internal
combustion industrial trucks”.
2.2.2 Main load-bearing structural components
2.2.2.1 Forklift
The main load bearing structural components of forklift trucks include frames,
masts, fork frames, and forks, which shall meet the following requirements.
(1) When the forklift carries 1.33 times the rated lifting weight or eccentric
load, the main load bearing structural components have sufficient
strength and rigidity;
combustion forklifts shall avoid causing discomfort to the operator;
(4) The battery forklift shall have a space of 30 mm or more between the
metal cover plate of the battery and the live part of the battery. When
there is an insulation layer between the cover plate and the live part, the
gap is at least 10 mm;
(5) The internal combustion forklift shall select the engine that meets the
requirements of the relevant emission standards;
(6) For the forklifts with explosion-proof function, the installed internal
combustion engine shall comply with GB 20800.1-2006 “General rules of
explosion-protect techniques of reciprocating internal combustion
engines for explosive atmospheres - Part 1. Group II engines for use in
flammable gas and vapor atmospheres”, GB 20800.2-2006 “General
rules of explosion-protect techniques of reciprocating internal
combustion engines for explosive atmospheres - Part 2. Group II engines
for use in flammable dust atmospheres”.
2.2.4.1.2 Sightseeing vehicles
(1) The maximum climbing grade designed for the sightseeing vehicle shall
not be less than 15%;
(2) The maximum climbing grade designed for the sightseeing train shall not
be less than 7%;
(3) The rated load is calculated by multiplying the rated number of
passengers by 85 kg (Note 2-1).
Note 2-1. The total weight of each passenger is calculated as 85 kg. The weight
of each passenger is 75 kg, and the sum of the average weight of each
passenger’s hand-carried and carry-on baggage is 10 kg.
2.2.4.2 Forklift transmission system
(1) For mechanical transmission forklifts, shifters shall have synchronizer;
(2) For hydraulic transmission forklifts, it shall have inching function;
(3) For static pressure transmission forklift, the engine can only be started
when it is in braking state;
(4) The internal combustion forklift shall be equipped with a device that
prevents the engine from starting when the transmission is engaged.
2.2.4.3 Steering and operation systems
2.2.4.5.2 Forklift
(1) The performance of the brake shall comply with GB/T 18849-2011
“Powered industrial trucks - Brake performance and component strength”;
(2) Forklifts that use pedals to operate the operation and brake control
devices shall comply with GB/T 26562-2011 “Construction and layout of
pedals of self-propelled sit-down rider-controlled industrial trucks - Rules
for the construction and layout of pedals”.
2.2.4.5.3 Sightseeing vehicles
(1) The service brake system shall use double pipes or multiple pipes;
(2) Braking force shall ensure that the braking distance and braking stability
meet the requirements of clause 5.5.7 in GB/T 21268-2014 “General
technical conditions for garden patrol minibus”;
(3) The braking force can ensure that the vehicle is parked in the up and
down direction of the maximum climbing grade under the condition of
rated load;
(4) The braking force can ensure that it can make parking the braking in the
downward direction of the designed maximum climbing gradient at the
rated load and the maximum operating speed.
2.2.4.6 Electrical and control systems
2.2.4.6.1 General requirements
(1) The switching device shall be set up for start-up of the field vehicle, which
may only be started by a key, password or magnetic card;
(2) The battery field vehicle’s control system shall have undervoltage,
overcurrent, overheating and overvoltage protection functions;
(3) The electric system of the battery field vehicle shall adopt a two-wire
system to ensure good insulation, and the control part shall be reliable.
2.2.4.6.2 Forklift
(1) The counterbalanced forklift shall be equipped with headlamp, brake
lights, turning signal lamps, and other lighting and signaling device, other
forklifts shall be equipped with the lighting and signaling devices based
on the conditions of use;
(2) The battery forklift shall be provided with an emergency power off switch
that is not automatically reset but can cut off the total control power supply,
lateral slipping and falling off of the cargo forks;
(3) Forklifts with explosion-proof function shall have the function of
mechanical explosion protection. Sparks shall not be generated on all
surfaces of working devices that come into contact with or may contact
the ground or the load. Materials used shall be copper, copper-zinc alloys,
stainless steel, etc., or they shall be wrapped by non-metallic material
(such as rubber or plastic).
2.2.5 Safety protection devices
2.2.5.1 General requirements
The field vehicle shall be equipped with warning devices and rearview mirrors
that can emit clear sound.
2.2.5.2 Forklift
(1) Safety belts and other restraint devices shall be installed on the driver's
position of a seated vehicle;
(2) The top guard shall meet the requirements of GB/T 5143-2008 “Industrial
trucks - Overhead guards - Specification and testing”;
(3) A falling speed limiting device and a self-locking device for the gantry
shall be provided. If the falling speed limiting valve and the lifting cylinder
are connected by a hose, there shall also be a device for preventing the
hose from breaking;
(4) The lifting device shall be provided with the overtravel prevention device
and limiter, to avoid accidental detachment of the moving parts from the
fork carriage and the gantry;
(5) Retaining racks and wheel guards shall comply with the requirements of
clause 4.7.5 and clause 4.9.2 of GB 10827.1-2014 “Industrial trucks -
Safety requirements and verification - Part 1. Self-propelled industrial
trucks, other than driverless trucks, variable-reach trucks and burden-
carrier trucks”;
(6) For the forklift battery, the battery insulation resistance is not less than
50Ω multiplied by the rated voltage of the battery pack (unit is V), the
insulation resistance of other electrical equipment is not less than 1kΩ
multiplied by the battery pack rated voltage value;
(7) In the case of open type rim and pneumatic tires, the structure shall be
such that the rim bolts are loosened only after the wheels have been
removed from the vehicle.
(3) Equipment, facilities, and workplaces that are compatible with production;
(4) Sound quality assurance system, safety management and post
responsibility system;
(5) The forklift manufacturing organization shall have the test and inspection
device for the whole vehicle, including at least braking performance test
instruments or devices, standard loads, test ramps, etc.;
(6) The manufacturing organization of the sightseeing vehicle shall have the
test and inspection device for the whole vehicle, including at least the
braking performance test instrument or device, test ramp, and lateral
rolling performance test device.
2.3.2 Process documents and job instructions
The manufacturing and repairing organization shall, in accordance with the
design documents, formulate a complete process document and work
instructions (blanking, machining, welding, assembly, spraying, incoming
inspection, process inspection, exit-factory inspection, etc.) to meet the
requirements of safety technical specifications and relevant standards, design
files.
2.3.3 Manufacturing, retrofitting, repair process and records
2.3.3.1 General requirements
(1) The manufacturing and repairing organization shall, in accordance with
the requirements of the process documents and work instructions, carry
out the manufacturing, retrofitting and repair activities and record them;
(2) The manufacturing organization shall record the traceable information of
the main components such as the frame, motor, engine, and controller;
(3) The manufacturing organization shall number the frame of the field
vehicle; the frame number shall be unique and marked on the obvious
position of the frame for easy identification.
2.3.3.2 Production of main load bearing structural components
2.3.3.2.1 Welding procedure qualification
The welding procedure documents shall be prepared prior to the welding of the
main load bearing structural components. In any of the following cases, welding
procedure qualification shall be carried out in accordance with relevant
regulations.
(1) In case of first execution of the welding procedure;
(4) The tire specifications and patterns on the same axle shall be the same,
and the tire specifications meet the design requirements;
(5) The knuckle and arm in the steering device, the steering crossbar, the
straight bar, and ball pin shall not have cracks or damage. The crossbar
and straight bar are not allowed to have butt welding, and the ball pin
shall not be loosened;
(6) When the forklift is traveling at the maximum speed in a straight line,
there shall be no obvious crawling phenomenon;
(7) The sealing parts of the ball joints of the suspension system for
sightseeing vehicles shall not have incisions and cracks, the stabilizing
bar shall be connected reliably; the structural parts shall not be deformed
or damaged;
(8) The shock absorbers for sightseeing vehicles are complete and effective,
and there must be no obvious leakage of oil;
(9) There is no deformation and crack in the front and rear axles of
sightseeing vehicles;
(10) When the sightseeing vehicle travels along a stra...