No single procedure provides a complete picture of a gearbox‘s condition. Only the interaction of multiple testing methods makes emerging damage visible early on – and thus predictable, before it leads to a standstill of the ropeway system.

Kissling AG combines four mutually complementary methods.

1. Visual inspection

The starting point is the visual inspection – either through the inspection ports or, more thoroughly, on the opened gearbox.

The contact pattern of the gearing, backlash, bearing clearance, loose elements, and the lubrication system are assessed. The gears are tested for cracks using the dye penetrant method.

2. Acoustic testing

Noises reveal irregularities that the eye cannot see: rough running, misalignment of the drive shaft, imbalance, loose components, cracks, or tooth breakages. Bearing damage can be located acoustically at an early stage – though if the damage is audible, it is usually already advanced.

3. Lubrication and oil analysis

Lubrication is one of the decisive factors for service life. A significant portion of all failures is due to insufficient or incorrect lubrication; therefore, flow and pressure monitoring are also checked for correct adjustment and function.

Regular oil analysis makes abrasion and wear measurable.

4. Vibration diagnosis

Vibration analysis, which is widely used today, rounds off the picture and, together with the other data, allows for time-based maintenance planning.

The sandblasted gearbox is inspected for material cracks by Kissling AG using UT/MT (ultrasonic / magnetic particle testing).

Data as a supplement

The assessment only becomes complete with the operator‘s specifications – operating hours, oil quality, leaks, and anomalies on the input and output sides. From this overall picture, Kissling AG derives which measures a gearbox needs to ensure it continues to run reliably.

Scope of the overhaul

Depending on the findings, the customer then orders a factory overhaul of the gearbox listed above for the purpose of preventive maintenance. During this process, all bearings and seals are replaced, and all shafts, bores, and geared parts are checked for dimensional accuracy (fits) and condition.

Dismantling

In the first step, the remaining oil is drained and the gearbox is dismantled. The parts are then sandblasted and cleaned and – as mentioned above – tested for condition and dimensional accuracy, especially the output and hollow shafts.

In addition, all geared components are inspected for cracks.

Findings

Depending on the findings, bearings, output shafts, wheels, pinion shafts, and the bevel gear set are replaced. In addition, parts are chrome-plated. If required, painting or further measures are carried out.

Assembly

After a successful overhaul, the gearbox is reassembled and the bevel gear set is adjusted. Subsequently, settings, clearance, and circulating lubrication are checked, and a test run is performed.

About Kissling AG

Kissling AG is a long-established Swiss company based in Bachenbülach, representing the highest level of competence in gearbox manufacturing.

The company covers a broad spectrum: from standard solutions for industrial applications to ropeway gearboxes and highly complex special and turbo gearboxes for demanding fields of application. Kissling consistently relies on customized solutions, state-of-the-art technologies, and the highest quality standards, certified according to ISO 9001 and ISO 14001, among others.

Thanks to international sales and service activities as well as a strong customer orientation, Kissling AG is a valued partner worldwide. The company combines tradition with an innovative spirit and continuously develops new solutions to meet the increasing demands of modern drive technology.