New safety directives for mechanical power transmission systems in 2026: a technical guide for Ukrainian enterprises

Introduction

Modernization of industrial equipment and bringing it into line with European standards is a critical task for Ukrainian manufacturing enterprises. In 2026, updated European Union directives and harmonized standards for the safety of mechanical power transmission systems come into force. These requirements directly affect the operation of gearboxes, couplings, belt and chain gears. Ignoring the new regulations leads not only to the stoppage of production lines, but also to serious legal consequences for the management of enterprises. The reliability and safety of drives is now measured not only by their duration of operation before failure (MTBF from 50,000 hours), but also by the full package of accompanying certification.

Scope of application

The new regulatory requirements apply to the entire spectrum of heavy and medium engineering, mining and beneficiation plants, cement plants, chemical industry enterprises and the food industry in Ukraine. Equipment subject to mandatory technical audit and revision includes:

• Cylindrical, bevel-cylindrical and planetary gearboxes with a torque of more than 500 Nm.
• Open gears and cardan shafts of the drive with a power of 45 kW or more.
• Braking and emergency shutdown systems on conveyor lines.
• Chain and belt transmissions located at a height of up to 2.5 meters from the floor level or service platforms.

Key requirements and standards

The updated regulatory framework is based on European standards implemented in the national legislation of Ukraine. The table below shows the main standards governing the safety of manual transmissions in 2026.

Impact on MRO operations

Changes in legislation require a review of standard maintenance, repair and operations (MRO) procedures. Reliability engineers and chief mechanic services must adapt internal regulations:

1. Retention of documentation: Each drive component must have a digital passport card with proven origin and a CE / UkrSEPRO certificate of conformity.
2. Lockout Procedures (LOTO): Updated instructions for energy isolation of equipment before starting repair work on reducers or couplings.
3. Condition monitoring: Implementation of vibration control (according to ISO 10816 / ISO 18436) for early detection of wear of bearings and couplings with a permissible vibration level of up to 4.5 mm/s.

Requirements for components

Not all replacement parts are suitable for upgrading to 2026 standards. Certification requirements cover critical nodes:

• Gear and planetary gearboxes: Wheel materials must have ultrasonic inspection protocols for the absence of internal defects (quality class according to ISO 6336).
• Connecting couplings: Must have explosion protection certificates (ATEX) if necessary and built-in overload protection elements (shear pins, hydraulic couplings with fusible plugs).
• Bearing assemblies: Use of high-strength cast iron housings (EN-GJS-400-15) instead of gray cast iron to prevent sudden brittle failure under shock loads.

Compliance checklist for engineers

A practical checklist for checking the condition of mechanical power transmission systems in production:

• [ ] Checked the presence and integrity of all belt and chain gear protective covers.
• [ ] The guards are equipped with limit switches with locking (safety category PL d according to EN ISO 13849-1).
• [ ] A visual control of the gearbox housing was carried out for the absence of cracks and lubricant leaks at an operating temperature of up to 85 °C.
• [ ] The torque of the bolted connections of the drive foundation frames was checked using a dynamometric tool.
• [ ] Centering of the electric motor and gear shafts with permissible radial runout of less than 0.05 mm was performed.
• [ ] The lubricant level in the gearbox corresponds to a nominal stained glass (lubricant purity class not lower than ISO 4406 18/16/13).
• [ ] Availability of "Stop" emergency switches at a distance of no more than 3 meters from any conveyor service point.
• [ ] Marked shaft rotation directions according to ISO 12100.
• [ ] A thermal imaging examination of the bearing units was carried out (the body temperature does not exceed 75 °C).
• [ ] A logbook of operating hours has been introduced for critical gearboxes (scheduled overhaul after 35,000 - 50,000 hours).
• [ ] Availability of certificates of origin and passports for all spare parts installed in the last 12 months.
• [ ] Trained staff on LOTO (Lockout/Tagout) procedures for stopping mechanical drives.
• [ ] Grounding of electric motors and gearboxes is checked (circuit resistance is less than 4 ohms).
• [ ] Absence of extraneous noises and knocking in gear engagement at idle.
• [ ] Availability of fire extinguishing equipment near hydraulic stations and lubrication systems.

Typical violations

Industrial safety auditors most often record the following inconsistencies at Ukrainian enterprises:

• Dismantling of protective covers for "quick access" during maintenance and their absence on a permanent basis.
• Using uncertified couplings or bearings of unknown origin without accompanying documentation.
• Lack of safety locks on service hatches of gearboxes.
• Exceeding the limits of vibration without stopping the equipment for diagnostics.

Penalties and liability

Violation of the safety standards of mechanical transmissions in 2026 entails severe sanctions. According to the Code of Ukraine on Administrative Offenses and the Law of Ukraine "On Labor Protection":

• Financial fines for enterprises for the operation of uncertified equipment amount to 5% to 10% of the annual income from the sale of products of the corresponding division.
• Suspension of production workshops for a period of up to 90 days by decision of the State Labor Service of Ukraine until the violations are completely eliminated.
• Criminal liability of officials (chief engineer, workshop manager) in the event of an accident due to the absence of protective fences or emergency interlocks (Article 271 of the Criminal Code of Ukraine — imprisonment for a term of up to 7 years).
• Final refusal of insurance companies to pay compensation in case of accidents on equipment that does not meet EN / ISO standards.

Conclusion

Ensuring compliance with the new 2026 safety directives requires a systematic approach to the selection of spare parts and the organization of maintenance processes. The use of certified components guarantees uninterrupted operation of the enterprise and protects against legal risks. To choose reliable, certified reducers, couplings and drive elements that meet European quality standards, we advise you to visit the UNITEC-D E-Catalog.

List of regulatory references

1. Directive 2006/42/EC of the European Parliament and the Council on the safety of machines and mechanisms.
2. DSTU EN ISO 12100:2016 Machine safety. General design principles. Risk assessment and risk reduction (ISO 12100:2010, IDT).
3. DSTU EN ISO 14120:2017 Machine safety. Protective fences. General requirements for the design and manufacture of stationary and mobile fences (EN ISO 14120:2015, IDT).
4. DSTU EN ISO 13849-1:2016 Machine safety. Safety-related details of control systems. Part 1. General design principles (EN ISO 13849-1:2015, IDT).
5. ISO 6336:2019 Calculation of the strength of cylindrical gears.