{"id":2789,"date":"2024-03-07T14:57:25","date_gmt":"2024-03-07T13:57:25","guid":{"rendered":"https:\/\/www.bf-hydraulik.com\/encyclopedia\/machine-safety-in-hydraulic-systems\/"},"modified":"2026-04-15T11:52:52","modified_gmt":"2026-04-15T09:52:52","slug":"machine-safety-in-hydraulic-systems","status":"publish","type":"encyclopedia","link":"https:\/\/www.bf-hydraulik.com\/en\/machine-safety-in-hydraulic-systems\/","title":{"rendered":"Machine Safety in Hydraulic Systems"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"2789\" class=\"elementor elementor-2789 elementor-931\">\n\t\t\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-735b55f8 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"735b55f8\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-50 elementor-top-column elementor-element elementor-element-2820cb8b\" data-id=\"2820cb8b\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-9fb9997 elementor-widget elementor-widget-text-editor\" data-id=\"9fb9997\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h1>Machine Safety in Hydraulic Systems<\/h1><p><a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-system\/\" target=\"_self\" title=\"Hydraulic system: design &amp; applications explained simplyA hydraulic system is used to apply large forces in a targeted manner over a defined distance with minimal effort. The underlying hydraulic principle&hellip;\" class=\"encyclopedia\">Hydraulic system<\/a>s are the preferred choice for generating large, directed forces. Whether for a <a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-press\/\" target=\"_self\" title=\"Hydraulic Press: Design, Applications and SizesThe hydraulic press is used when very high forces must be applied to a workpiece, for example, to perform forming operations.Its disadvantage is that it&hellip;\" class=\"encyclopedia\">hydraulic press<\/a>, lifting platform, or excavator boom, hydraulics offers simple, flexible, and quickly implementable solutions for every challenge. <\/p><p>However, <a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-system\/\" target=\"_self\" title=\"Hydraulic system: design &amp; applications explained simplyA hydraulic system is used to apply large forces in a targeted manner over a defined distance with minimal effort. The underlying hydraulic principle&hellip;\" class=\"encyclopedia\">hydraulic system<\/a>s also pose dangers that must be considered during their operation. To enhance <a href=\"https:\/\/www.bf-hydraulik.com\/en\/machine-safety-in-hydraulic-systems\/\" target=\"_self\" title=\"Machine Safety in Hydraulic SystemsHydraulic systems are the preferred choice for generating large, directed forces. Whether for a hydraulic press, lifting platform, or excavator boom, hydraulics offers simple, flexible, and&hellip;\" class=\"encyclopedia\">machine safety in hydraulic systems<\/a> and keep them as safe as possible for the operator, numerous standards and laws have been developed. <\/p><h2>What Dangers Do Hydraulic Systems Pose?<\/h2><p>A <a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-system\/\" target=\"_self\" title=\"Hydraulic system: design &amp; applications explained simplyA hydraulic system is used to apply large forces in a targeted manner over a defined distance with minimal effort. The underlying hydraulic principle&hellip;\" class=\"encyclopedia\">hydraulic system<\/a> does not appear particularly threatening. The work processes are barely visible from the outside, and movements appear relatively slow. Evading approaching actuators always seems possible. However, this is only true as long as the system operates within desired limits. Malfunctions in <a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-system\/\" target=\"_self\" title=\"Hydraulic system: design &amp; applications explained simplyA hydraulic system is used to apply large forces in a targeted manner over a defined distance with minimal effort. The underlying hydraulic principle&hellip;\" class=\"encyclopedia\">hydraulic system<\/a>s can have the following consequences:     <\/p><ul><li>spurting hot hydraulic fluid<\/li><li>bursting housings<\/li><li>whipping hoses<\/li><li>fire hazard due to overheating<\/li><li>sudden lowering of actuators due to pressure loss<\/li><\/ul><h3>When is Machine Safety in Hydraulic Systems Compromised?<\/h3><p>If a leak occurs in a <a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-system\/\" target=\"_self\" title=\"Hydraulic system: design &amp; applications explained simplyA hydraulic system is used to apply large forces in a targeted manner over a defined distance with minimal effort. The underlying hydraulic principle&hellip;\" class=\"encyclopedia\">hydraulic system<\/a>, the working fluid escapes. Depending on the operating pressure, temperature, and size of the leak, the fluid jet can pose a high risk of injury and scalding. <\/p><p>Excessive pressure can cause not only lines and hoses to burst, but also the housings of pumps, valves, or even tanks.<\/p><p>Tearing, unsecured hoses, while simultaneously spurting hydraulic oil, whip uncontrollably in all directions &ndash; an extremely dangerous situation.<\/p><p>Inadequate heat dissipation can lead to heat buildup, which in turn can trigger a fire or an explosion.<\/p><p>Pressure loss in an excavator arm or a lifting platform, without safety measures, leads to the immediate collapse of the often multi-ton weight. This poses an extreme danger to life for all bystanders. <\/p><h3>How Machine Safety in Hydraulic Systems Can Be Ensured:<\/h3><p><a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-system\/\" target=\"_self\" title=\"Hydraulic system: design &amp; applications explained simplyA hydraulic system is used to apply large forces in a targeted manner over a defined distance with minimal effort. The underlying hydraulic principle&hellip;\" class=\"encyclopedia\">Hydraulic system<\/a>s are subject to the Machinery Directive. This standard forms the basis for occupational safety law. Operators and manufacturers of <a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-system\/\" target=\"_self\" title=\"Hydraulic system: design &amp; applications explained simplyA hydraulic system is used to apply large forces in a targeted manner over a defined distance with minimal effort. The underlying hydraulic principle&hellip;\" class=\"encyclopedia\">hydraulic system<\/a>s are therefore obliged to implement constructive measures that make the machines as safe as possible.<br>As in mechanical engineering, the &ldquo;three-step safety concept&rdquo; underlies the safe design of <a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-system\/\" target=\"_self\" title=\"Hydraulic system: design &amp; applications explained simplyA hydraulic system is used to apply large forces in a targeted manner over a defined distance with minimal effort. The underlying hydraulic principle&hellip;\" class=\"encyclopedia\">hydraulic system<\/a>s. Simply put, it states the following:   <\/p><ol><li>Design the machine to be as safe as possible.<\/li><li>Mitigate what cannot be made structurally safe through constructive measures.<\/li><li>Document what cannot be mitigated with warning signs.<\/li><\/ol><p>A safe design for a <a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-system\/\" target=\"_self\" title=\"Hydraulic system: design &amp; applications explained simplyA hydraulic system is used to apply large forces in a targeted manner over a defined distance with minimal effort. The underlying hydraulic principle&hellip;\" class=\"encyclopedia\">hydraulic system<\/a> is given, for example, when all components can withstand the expected peak pressure multiple times over. Creeping cracks and sudden bursting of housings are practically ruled out with this over-dimensioning. <\/p><p>Constructive measures include, for example, housings or hose burst protection. Warning signs, which, for instance, warn of hot spots or prescribe protective equipment, are only the &ldquo;last resort.&rdquo; <\/p><p>Further information on the safe design of <a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-system\/\" target=\"_self\" title=\"Hydraulic system: design &amp; applications explained simplyA hydraulic system is used to apply large forces in a targeted manner over a defined distance with minimal effort. The underlying hydraulic principle&hellip;\" class=\"encyclopedia\">hydraulic system<\/a>s can be found, for example, in the Pressure Equipment Directive or DIN EN ISO 4413:2011-04 &ldquo;Fluid power systems &ndash; General rules and safety requirements for <a href=\"https:\/\/www.bf-hydraulik.com\/en\/hydraulic-system\/\" target=\"_self\" title=\"Hydraulic system: design &amp; applications explained simplyA hydraulic system is used to apply large forces in a targeted manner over a defined distance with minimal effort. The underlying hydraulic principle&hellip;\" class=\"encyclopedia\">hydraulic system<\/a>s and their components.&rdquo;<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t<div class=\"elementor-column elementor-col-50 elementor-top-column elementor-element elementor-element-17578f6\" data-id=\"17578f6\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t<div class=\"elementor-element elementor-element-18d5d30 elementor-widget elementor-widget-sidebar\" data-id=\"18d5d30\" data-element_type=\"widget\" data-widget_type=\"sidebar.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<div style=\"display:none;\">Search<\/div><form role=\"search\" method=\"get\" class=\"encyclopedia search-form\" action=\"https:\/\/www.bf-hydraulik.com\/en\/encyclopedia\/\">\n    \n    \n    <label class=\"screen-reader-text\" for=\"encyclopedia-search-term\">Search<\/label>\n    <input 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