Introduction and General

Servicing
Machine Safety
Section 1-1

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 Safety Matters

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 Safety Rules
● Only trained and authorized personnel can operate and
maintain the machine.
● Follow all safety rules, precautions and instructions when
operating or performing maintenance on the machine.
● Do not operate the machine while taking medication that
may cloud your thoughts.
● When working with another operator or with a person on
work site traffic duty, be sure that all personnel
understand all hand signals that are to be used.
● Always follow all rules related to safety.

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 Safety Features
● Be sure all guards and covers are in their
proper position. Have guards and covers
repaired if damaged.
● Use safety features such as safety lock levers
and the seat belt properly.
● Never remove any safety features. Always
keep them in good condition.
 Safety Lock Lever
 Seat Belt
● Improper use of safety features could result in
serious bodily injury or death.

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 Clothing and Personal Protective Items

Avoid loose clothing, jewelry and loose long
hair. They can catch on controls or in moving
parts and cause serious injury or death.

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 When 　 Leaving 　 Machine

・ Always Apply Parking

・ Always Apply All Safety Locks

・ Always Keep Work equipment to

the ground

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 Mounting and Dismounting

● Never jump on or off a machine. Never get on

or off a moving machine.
● When getting on or off the machine, always
face the machine and use the handrails and
steps.
● Never hold any control levers or lock levers
when getting on or off the machine.

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Mounting and Dismounting (Cont’d)

● If there is any oil, grease, or mud on the

handrails or steps, wipe it off
immediately.
● Always keep these parts clean.
● Repair any damage and tighten any
loose bolts.

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 Fire Prevention For Fuel and Oil
Fuel, oil, and antifreeze are
particularly flammable and can
be hazardous.
● Do not smoke or use flame near fuel
or oil.
● Stop the engine when refueling.
● Do not leave machine while adding
fuel or oil.
● Tighten all fuel and oil caps securely.
● Do not spill fuel on overheated
surfaces or on parts of the electrical
systems.
● Use well ventilated areas for adding
or storing oil and fuel.

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Fire Prevention For Fuel and Oil (Cont’d)
● Keep oil and fuel in the determined place and do not allow
unauthorized person to enter.
● After adding fuel or oil, wipe up any spilled fuel or oil.
● When carrying out grinding or welding work on the chassis,
move any flammable materials to a safe place before starting.
● When washing parts with oil, use a non-flammable oil. Diesel
oil and gasoline may catch fire, so do not use them.
● Put greasy rags and other flammable materials into a safe
container to maintain safety.
● Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.

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 Precautions When Dealing With Temperatures

● Immediately after operations are stopped, the engine

oil and hydraulic oil are at high temperature and are
still under pressure.
● Attempting to remove the cap, drain the oil or water,
or replace the filters may lead to serious burns.
● Always wait for the temperature to go down, and
follow the specific procedures when carrying out
these operations.

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 Hot Water

To prevent hot water from spurting
out, stop the engine, wait for the
water to cool, then loosen the cap,
slowly to relieve the pressure before
removing the cap.
 When checking if the water
temperature has gone down, put your
hand near the front face of the
radiator and check the air
temperature. Be careful not to touch
the radiator.

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 Hot Oil
● To prevent hot oil from spurting out, stop the engine, wait for the
oil to cool, then loosen the cap slowly before removing the cap.
● When checking if the oil temperature has gone down, put your
hand near the front face of the hydraulic tank and check the air
temperature. Be careful not to touch the hydraulic tank.

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 Crushing or Cutting Prevention
● Do not enter, or put your hand or
arm or any other part of your body
between moveable parts such as
the work equipment and cylinders,
or between the machine and the
work equipment.
● If the work equipment is operated,
the clearance will change and this
may lead to serious damage or
personal damage.
● If it is necessary to go between
moveable parts, always lock the
levers and be sure the work
equipment cannot move.
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Fire Extinguisher and First Aid Kit

Always follow the precautions

below to prepare for action if any
injury or fire should occur.
Be sure that fire extinguishers have
been provided and read the labels
to ensure you know how to use
them.
Provide a first aid kit at the storage
point. Check periodically; add to
the contents when necessary.

Know what to do in the event of a

fire or injury.

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Fire Extinguisher and First Aid Kit (Cont’d)

● Decide the phone number

(Doctor, ambulance, fire
station, etc) to contact in
case of an emergency.
● Post these contact
numbers in specific places.
● Make sure that all
personnel know the
numbers and correct
contact procedures.

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 Precautions for ROPS
● Do not operate machine with ROPS (Roll Over Protection)
removed if equipped.
● The ROPS is installed to protect the operator if the machine
should turn over. It is designed not only to take the load when
turns over, but also to absorb the impact energy.
● The Komatsu ROPS fulfills all worldwide regulations and
standards, but if any unauthorized modification is carried out on it,
or if it is damaged when the machine turns over, its strength will
be reduced and it will not be able to provide its original capacity. It
will be able to provide this capacity only if modifications and
repairs are carried out in the specified way.

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 Precautions for ROPS (Cont’d)

● When carrying out

modification or repairs,
always consult your
Komatsu Distributor first.
● Even when the ROPS is
installed, if you do not fasten
your seat belt, it cannot
protect you properly. Always
fasten your seat belt when
operating the machine.

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 Precautions for Attachments
● When installing and using an optional attachment, read the
instruction manual for the attachment and the information
related to attachments in the manual.
● Do not use attachments that are not authorized by
Komatsu or your Komatsu distributor. Use of unauthorized
attachments could create a safety problem and adversely
affect the proper operation and useful life of the machine.
● Any injuries, accidents, product failures resulting from the
use of unauthorized attachments will not be the
responsibility of Komatsu.

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 Ventilation for Enclosed Areas
Exhaust Fumes From the Engine Can Kill
● If it is necessary to start the engine within an
enclosed area, or you handle fuel, flush oil, or
paint, open the doors and windows to ensure
that you provide adequate ventilation to
prevent gas poisoning.
● If opening the doors and windows still does
not provide adequate ventilation, set up fans.

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 Before Starting Engine

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 Safety at Work Site
● Before starting operations, thoroughly check the area for
any unusual conditions that could be dangerous.
● Check the terrain and condition of ground at the work site,
and determine the best and safest method of operation.
● Make the ground surface as hard and horizontal as
possible before carrying out operations. If the job site is
dusty, spray water before starting operations.
● If you need to operate on a road, protect pedestrians and
cars by designating a person to work site traffic controller
or by installing fences and putting up “No Entry” signs
around the work site.

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 Safety at Work Site (Cont’d)
 If water lines, gas lines, or high voltage
electrical lines may be buried under the work
site, contact each utility and identify their
locations. Be careful not to sever or damage
any of these lines.


Check the ground condition and the depth and
flow of water before operating in water or
crossing a river. Never be in water which is
excess of the permissible water depth as shown
in Operation and Maintenance Manual.

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Checks Before Starting Engine
 Carry out the following checks before starting the engine
at the beginning of the days work.

Failure to carryout these checks may lead to serious
injury or damage.
● Completely remove all flammable materials accumulated
around the engine and battery, return all fuel containers to
their proper place, remove all parts and tools from the
operator’s compartment, and remove any dirt from the
mirrors, handrails and steps.
● Check the coolant level, and oil level in the hydraulic tank,
check for clogging of the air cleaner, and check the electric
wiring.

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 Checks Before Starting Engine (Cont’d)

● Adjust the operators seat to a position

where it is easy to carryout operations, and
check for wear or damage to the seat belt
and seat belt mounting equipment.
● Check the gauges work properly, and
check that the control levers are all at the
NEUTRAL position.
● Check that the mirrors and window glass
provide a clear view.
● If the above inspections show an
abnormality, carry out repairs immediately.

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 When Starting Engine

Just prior to mounting your machine, walk

around it again to check for people and objects
that might be in the way

Never start the engine if a warning tag has been

attached

When starting the engine, sound the horn

as an alert

Start and operate the machine only while seated

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 When Starting Engine (Cont’d)

● Do not allow anyone to ride on the machine body.

Passengers may only be carried where additional
seating is provided.
● Do not short circuit the starting motor to start the
engine. It is not only dangerous, but will also cause
damage to the equipment.

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 After Starting Engine

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Checks After Starting Engine

● Failure to carry out the checks properly after starting the

engine will lead to delays in discovery of abnormalities, and
this may lead to serious injury or damage to the machine.
● When carrying out the checks, use a wide area where there
are no obstructions. Do not allow anyone near the
machine.
● Check the operation of the gauges and equipment, also
check the operation of the blade, brakes, travel system,
and steering system.
● Check for abnormality in the sound of the machine,
vibration, heat smell, or gauges; check also that there is no
leakage of air, oil or fuel.
● If any abnormality is found, carry out repairs immediately.

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 If the machine is used when it is
not in good condition, it may lead to
serious injury or damage to the
machine.

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 Precautions When Starting to Move

● Before moving the machine, check again that

there are no persons or obstacles in the
surrounding area.

● When moving the machine, sound the horn to

warn people in the surrounding area.

● Always sit in the operator’s seat when driving the

machine.

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 Precautions When Starting to Move (Cont’d)

● Fasten your seat belt securely.

● Check that the travel alarm (option) works

properly.

● Always close the door of the operator’s cab and

check that the door is locked in position securely.

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Precautions When Moving Forward or Backward

● To prevent serious injury or ● Check that there is no one

death, always do the near the machine. Be
following before moving the particularly careful to check
machine or doing the behind the machine.
leveling work. ● When operating in areas
● Before changing between that may be hazardous or
forward and reverse, have poor visibility,
reduce speed and stop the designate a person to direct
machine. work site traffic.
● Before operating the ● Ensure that no
machine, sound the horn to unauthorized person can
warn people in the area. come within the direction of
turning or travel.

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