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Item no.: 1001816.

R3 Issued by: Technology Type: Work Instruction

Replacement of Gearbox with Fixture, V82 – 1.65MW

Date 2007-07-23 Class: II Page 1 of 62

Replacement of Gearbox with Fixture, V82 – 1.65 MW
Prepared by: TKB Approved by: FSA Reference/Drawing See the section Required Documentation Work-place Service Business Unit Technology

History of this Document
Rev. no.: 1 2 3 Date: 2006-10-24 2007-01-12 2007-07-23 Description of changes First edition Extra history and table of contents removed Page 58: Benzene changed to Benzine Update of Item no for Safety Railing in tools list

Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.vestas.com

Item no.: 1001816.R3 Issued by: Technology Type: Work Instruction

Replacement of Gearbox with Fixture, V82 – 1.65 MW Table of Contents

Date 2007-07-23 Class: II Page 2 of 62

Table of Contents
1 2 3 4 5 6 7 8 9 10 11 11.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 11.13 11.14 11.15 11.16 11.17 11.18 11.19 11.20 12 12.1 13 14 15 16 Safety.......................................................................................................................................................3 Educational Requirements of Technician............................................................................................3 Required Documentation.......................................................................................................................3 Purpose ...................................................................................................................................................3 Risk Assessment....................................................................................................................................3 Note..........................................................................................................................................................5 Tools ........................................................................................................................................................5 Spare Parts..............................................................................................................................................8 Weights....................................................................................................................................................8 Estimated Time Use ...............................................................................................................................8 Procedure................................................................................................................................................9 Preparing of rotor lock ..............................................................................................................................9 Preparing of fixture ...................................................................................................................................9 Lifting equipment for the Gearbox and adjustment to the right angle ...................................................14 Various preparing in the nacelle............................................................................................................15 Stripping of gearbox ...............................................................................................................................23 Slip ring unit and rotating union..............................................................................................................29 Rotor lock ...............................................................................................................................................31 Centa Link Coupling ...............................................................................................................................36 Moving the generator .............................................................................................................................39 Preparing in the hub ...............................................................................................................................39 Hoses to the coolers on the roof ............................................................................................................42 Cables and wires....................................................................................................................................44 Shrink disc ..............................................................................................................................................45 Torque arms ...........................................................................................................................................48 Nacelle cover..........................................................................................................................................49 Mounting the main shaft fixture ..............................................................................................................53 Preparing the new gearbox ....................................................................................................................58 Switching gearboxes ..............................................................................................................................61 Installing the nacelle cover .....................................................................................................................62 Tightening the shrink disc.......................................................................................................................62 Reinstalling the nacelle and hub components..................................................................................62 Dismounting the rotor lock......................................................................................................................62 Alignment of gearbox and generator .................................................................................................62 Preparation of the old gearbox ...........................................................................................................62 Check points .........................................................................................................................................62 Start up ..................................................................................................................................................62

Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.vestas.com

Item no.: 1001816.R3 Issued by: Technology Type: Work Instruction

Replacement of Gearbox with Fixture, V82 – 1.65 MW Safety

Date 2007-07-23 Class: II Page 3 of 62

1

Safety

Vestas safety rules must be followed. See the Health and Safety Manual: 1000711. See also Risk Assessment. Maximum wind speed when using an external crane: 10m/s. Maximum wind speed at alignment of the generator: 8m/s. Wear protective glasses, hearing protector, hand protection (heat resistant gloves), safety helmet and safety shoes.

2

Educational Requirements of Technician

It is preferred to have at least one service technician with knowledge of gearbox replacement in this actual turbine type. At least 4 service technicians are required to do the gearbox replacement.

3

Required Documentation

1000711 Health and Safety Manual 5001097 Installation and Service Data Service Manual: 1001818: Check List for Replacement of gearbox Supplier drawing of Centa Link Coupling

4

Purpose

To replace a damaged gearbox on site.

5

Risk Assessment

Risk of falling to the ground from the nacelle
Danger to life due to the risk of falling out of the nacelle while working with the upper nacelle cover / roof dismantled. Never work without being hooked or without a safety rail. Make sure to be hooked onto two safe hooking points with two tackle ropes.

Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.vestas.com

Electric shock Risk of death or severe injury when touching wires with power. use only original parts authorised by Vestas. use rags to suck up dripping oil or cooling water.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. Always wear safety helmets with chain straps when the overhead crane is in operation.Item no. Be careful when working with gearboxes or other parts. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Never stand under a suspended load. Hearing damages Risk of hearing damages when using an electric impact wrench or similar tools.: 1001816. e.vestas.g. Do not touch wires unless you are sure that the power supply is off. Switch off power and check with a voltmeter that there is no power supply to the wires. Use hearing protector when working with very noisy tools. V82 – 1. a lifting chain brakes.g. Risk of fingers or other body parts getting caught or crushed Risk of getting fingers or other body parts caught or crushed when handling the gearbox or other parts.65 MW Risk Assessment Date 2007-07-23 Class: II Page 4 of 62 Crushing by falling load Danger to life due to a falling load if e. If replacing spare parts for lifting equipment. Make sure to wipe away spilled oil. stepping in spilled oil. Use only lifting equipment designed for the task. Slipping and falling Risk of person injury due to slipping and falling in the nacelle.com . Do not slip or fall in the nacelle.

It is recommended that the rotor is not locked for more than 48 hours.: 1001816.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. V82 – 1.Item no. like packing/ordering the necessary tools and spare parts This instruction is on the basis of a V82-1.com . read this work instruction carefully and prepare all the things you can do in advance.: Tools Quantity Text Live working gloves Electronic spirit level Bag for electronic spirit level 1 Lifting tool for shrink disc Safety railing NM 82 Lift-nacelle roof/ cooler Fixture Rotor lock Bayonet saw Blade for bayonet saw 150mm Blade for bayonet saw 225mm Hydraulic torque wrench heads MXT 10 Hydraulic torque wrench heads MXT 3 Hytorc pump with hoses Service crane 70 mm wrench 50mm wrench 46mm wrench 41mm wrench 36mm wrench 32mm wrench 30mm wrench 27mm wrench T2198900 1 T2191200 1 T2191300 VT742277 1 VT310241 1 301166 301111 1 1 T3699900 1 T3695100 1 301248 1 3 3 1 2 2 2 2 2 2 2 2 T3274600 2 Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. 7 Item no.65MW turbine. It is however allowed to carry out the work without safety railing if the technicians in the open nacelle are properly hooked onto approved anchor points. otherwise there is a risk of stand still marks on the main bearing. It is recommended to use a safety railing as described in this instruction.vestas.65 MW Note Date 2007-07-23 Class: II Page 5 of 62 6 Note Before starting the job. For NM64/NM72/NM82 turbines there are some differences.

17. 13.vestas.: Quantity 2 2 4 4 4 4 Text 24mm wrench 22mm wrench 19mm wrench 17mm wrench 13mm wrench 10mm wrench 8” adjustable wrench 12” adjustable wrench 18” adjustable s wrench Medium multigrips Large multigrips 90mm short.: 1001816. 30mm 3/4” impact allen sockets 10. 8mm ½” allen sockets 22. 19. V82 – 1. 27.Item no. ring impact wrench 90mm impact socket1 ½” 50mm impact socket 1 ½” 55mm impact socket 1 ½” 55mm 1” short impact socket 50mm 1” short impact socket 46mm 1” short impact socket 41mm 1” short impact socket 41mm 1” long impact socket 55mm 3/4 ” short impact socket 50 3/4 ” short impact socket 46 3/4 ” short impact socket 41 3/4 ” short impact socket 36 3/4 ” short impact socket 32 3/4 ” short impact socket 30 3/4 ” short impact socket 41mm ¾” long impact socket 6mm ½” .R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. 22.com . 24mm ½” sockets ¾” torque wrench up to 140-760 Nm ½” torque wrench up to 75-400 Nm 30mm ring spanner for ½” torque wrench ½” electric impact . cordless if possible ¾” electrical impact wrench Pairs of sidecutters Small flat and Phillips screwdrivers T2092400 2 T2092600 2 T2092800 2 2 2 4 T3275800 2 T3515800 2 T3689200 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 4 T2173000 1 T2175100 1 1 300350 2 2 8 4 Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.65 MW Tools Date 2007-07-23 Class: II Page 6 of 62 Item no.

Item no. big . 5m long Work lamps Large lifting bags Small lifting bags Lifting buckets 250 kg chain hoist 3T chain hoist with 1. Hansen EH 803 Small gas burner set to be used in the nacelle Chisel to screw out the 2 plugs in the shrink disc. 47) Ratchet lever hoists 250 Kg Hose clamp Angle grinder with discs Die grinder (fast rotating grinder) Sledge hammer Generator alignment equipment T3848200 2 2 4 4 6 T2183400 2 10 10 6 4 2 4 8 10 T3170200 8 T3170100 8 T3923100 2 4 VT730482 1 VT730760 1 1 2 301133 2 1 1 T2124500 1 1 Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.5T for the right bag side.65 MW Tools Date 2007-07-23 Class: II Page 7 of 62 Item no. gear V80/V82 Shackle 8.vestas.: 1001816. V82 – 1. (see Figure 11-55.: Quantity 4 4 Text Medium flat and Phillips screwdrivers Large flat and Phillips screwdrivers Multimeters Fluke Allen key set Medium size crowbars Hobby knifes with blades Extension cords with 3 sockets on the end. for the hollow shaft 12mm eye bolts Lifting chain F.com .5m chain 2m purple straps 1 T 6m green straps 2T Carbine clips Walkie talkies Charger for walkie talkie Gas burner. p.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.

17 T 10 Estimated Time Use The time use is dependent on the number of service technicians and how experienced they are.: 1001816. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. V82 – 1.65 MW Spare Parts Date 2007-07-23 Class: II Page 8 of 62 8 Item no.Item no. and situations like if the shrink disc and the brake disc have to be swapped over to the new gearbox or if these components are pre mounted.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.vestas.com . The time use is also dependent of the weather.: Site specific Spare Parts Quantity Text 1 Oil filter Blue paint RAL 5010 Black paint for the main shaft White paint for the nacelle cover Universal cloth/rags Oil Rags Cable ties Solid plastic bags for blacking off the oil hoses and fittings 60060119 1 1 1 226631 115517 198004 096189 213619 149752 233843 1 1 2 1 Cleaning paper Tork Multi Benzine Never Seez grease Sikaflex Adhesive RAL 9010 Emery cloth for the main shaft / hollow shaft Scotch Brite 3M M60 Washer 60072154 4 9 Weights Gearbox: approx.

2 Preparing of Fixture Figure 11-1: Fixture overview and parts 1 2 3 7 Crescent shaped flange against main bearing housing Hydraulic cylinders Distance pieces depending on turbine type Lower part of fixture body 4 5 6 Upper part of fixture body Crescent shaped flange against gearbox Distance block for second gearbox push Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Prepare the rotor lock on the ground.com . V82 – 1. and lift it up to the nacelle.Item no.: 1001816.65 MW Procedure Date 2007-07-23 Class: II Page 9 of 62 11 11.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.1 Procedure Preparing of Rotor Lock 1.vestas. 11.

Item no.com .65 MW Procedure Date 2007-07-23 Class: II Page 10 of 62 Figure 11-2: Parts in the gear pusher system 1 2 3 7 Two round rods Distance pieces depending on turbine type Crescent shaped flange against gearbox Connection tubes 4 5 6 Hydraulic cylinders Distance blocks for second hydraulic stroke Crescent shaped flange against main bearing housing Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.vestas.: 1001816. V82 – 1.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.

R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.65 MW Figure 11-4: Pusher system configuration for NM72/1500 & NM64/1500 Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.Item no. V82 – 1.com .: 1001816.65 MW Procedure Date 2007-07-23 Class: II Page 11 of 62 Figure 11-3: Pusher system configuration for NM82/1650 & V82-1.vestas.

Item no.: 1001816.vestas.5 MW use the thick plates.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. Figure 11-6: Mounting the distance plates Figure 11-7: Crescent shaped flange against the gearbox side Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. For a NM 64 1. p. For a V82 or a NM 72/82 Artic model. V82 – 1.65 MW Procedure Date 2007-07-23 Class: II Page 12 of 62 Figure 11-5: Distance blocks 2.com . use the medium thick plates. 12). Prepare the fixture so it fits the main shaft (Figure 11-5.

ready to be lifted up with the fixture. and the bottom distance plates. Pack relevant set of bolts in a tool bag.65 MW Procedure Date 2007-07-23 Class: II Page 13 of 62 NOTE Do not mount the bottom distance plates until the fixture is up on the main shaft.com . V82 – 1.Item no. Figure 11-8: Lifting equipment Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.vestas. Mount the lifting eyes and straps on the fixture.: 1001816. 3.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.

vestas. Measure the angle of the gearbox in the nacelle.65 MW Procedure Date 2007-07-23 Class: II Page 14 of 62 3 1 2 Figure 11-9: Fixture ready to lift up in the nacelle 1 2 Crescent shaped flange on the rotor side Hydraulic cylinders for pushing of the gearbox 3 Bolts are fastened together with cable ties 11. Use a digital spirit level (see Figure 11-10. V82 – 1. 0° sideways and 4. 5.3 Lifting Equipment for the Gearbox and Adjustment to the Right Angle 4.0° in longitudinal direction.Item no.5° to 5.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. 15).Yaw the nacelle into position for the mobile crane. p. It must be approx.: 1001816. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Stop the turbine and switch to “Service mode” .com .

vestas. Tighten it with cable ties to the generator. Get the total weight of the gearbox from the crane driver. do not perform the test lift to get the weight until the shrink disc and the brake arrangement have been swapped over. 7.65 MW Procedure Date 2007-07-23 Class: II Page 15 of 62 Figure 11-10: Measuring the angle in the longitudinal direction 6. 16).R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.: 1001816. V82 – 1.4 Various Preparations in the Nacelle 9. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. p. Dismantle the shielding on the main shaft and hang it on the generator as shown (see Figure 11-11.com .Item no. 8. If the new gearbox comes without shrink disc and brake disc. 11. Let the crane lift the gearbox free from the ground and adjust the angle of the gearbox in the chain hoists according to the angle measured on the old gearbox. Prepare the lifting equipment on the ground. Let the crane lift the lifting equipment onto the new gearbox and mount the equipment.

Disconnect the main power at the main disconnectors and the circuit breaker (see Figure 11-12. 17).R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. V82 – 1.: 1001816.com . p.65 MW Procedure Date 2007-07-23 Class: II Page 16 of 62 Figure 11-11: Main shaft shielding 10. p. 17) and (see Figure 11-13. NOTE There is still 230 V power on in the turbine. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.vestas.Item no.

Cut off the power to the AN6 cabinet and the big fan that the service technician is holding in the picture (see Figure 11-14. Dismantle the fan/heater in the right side of the main shaft and put it away (The fan is not mounted in all turbines. 18). 12. p.vestas.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. p.65 MW Procedure Date 2007-07-23 Class: II Page 17 of 62 Figure 11-12:Main power disconnections Figure 11-13: Circuit breaker 11.com . Check with a multi-meter that the power supply is off. V82 – 1. Cut off the power to the slip ring unit in the top controller and in general for all the electrical parts which are to be dismantled.: 1001816. Check with a Fluke that there is no power. only in Artic models) (see Figure 11-14. 13.Item no. 18) Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.

to make room for the fixture (see Figure 11-15. NOTE The AN6 cabinet is heavy and two service technicians must lift it together and place it out of the way.65 MW Procedure Date 2007-07-23 Class: II Page 18 of 62 2 1 Figure 11-14: 1 2 Fan mounted in Artic models Fan AN6 cabinet 14. p. only in Artic models).g.vestas.: 1001816.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.Item no.com . 15. Dismantle the AN6 cabinet and put it away e. 19). V82 – 1. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Dismantle a yaw motor in each side next to the two front yaw gear motors. at the yaw gears (The cabinet is not mounted in all turbines.

Dismantle the fitting on the main bearing.65 MW Procedure Date 2007-07-23 Class: II Page 19 of 62 Figure 11-15: Yaw motor dismantled 16. Dismantle the oil hose to the main bearing.Item no.: 1001816. V82 – 1. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.vestas.com .R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.

65 MW Procedure Date 2007-07-23 Class: II Page 20 of 62 2 1 3 Figure 11-16: 1 2 Oil hose Fitting that must be dismantled Oil hose to main bearing 3 Shielding at the main bearing 17. Dismantle the shielding at the main bearing around the main shaft (see Figure 11-16. p. 20).com .: 1001816.Item no. V82 – 1. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.vestas.

Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Dismantle the lightning conductor (see Figure 11-18.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. 22). V82 – 1.Item no. p.com .vestas. Dismantle the inductive sensors for rotor rpm (see Figure 11-19. p.: 1001816. Figure 11-17: Thread rods for shielding 19. 22). 20.65 MW Procedure Date 2007-07-23 Class: II Page 21 of 62 18. Dismantle the thread rods for the main bearing shielding (because the fixture is to face the edge of the main shaft.

Item no.: 1001816.R3 Issued by: Technology Type: Work Instruction

Replacement of Gearbox with Fixture, V82 – 1.65 MW Procedure

Date 2007-07-23 Class: II Page 22 of 62

Figure 11-18:

Lightning conductor

Figure 11-19:

Inductive sensor for rotor RPM

21. Dismantle the 230V / 110 V, CE sockets at the yaw gears (in the right side of the nacelle). Loosen the cable trays in both sides over the yaw gears and let them hang loosely (to get room for the fixture) (see Figure 11-20, p. 23).

Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.vestas.com

Item no.: 1001816.R3 Issued by: Technology Type: Work Instruction

Replacement of Gearbox with Fixture, V82 – 1.65 MW Procedure

Date 2007-07-23 Class: II Page 23 of 62

Figure 11-20:

Cable tray and CE sockets loosened

22. Loosen the shrink disc: The 8 bolts in the top and the 11 bolts in the bottom. Put off loosening the bolts in the sides. Use a Hytorc with a 50mm socket and an electrical impact wrench.

11.5

Stripping of Gearbox

23. Dismantle the wiring to the AN 12 junction box on the gearbox. Dismantle the box. NOTE Note down where the wires are placed.

Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.vestas.com

Item no.: 1001816.R3 Issued by: Technology Type: Work Instruction

Replacement of Gearbox with Fixture, V82 – 1.65 MW Procedure

Date 2007-07-23 Class: II Page 24 of 62

Figure 11-21:

AN12 junction box

Figure 11-22:

Dismantling wires in the AN12 box

24. Dismantle the wires to the PT 100 sensors in the gearbox. Some are placed on top of the gearbox and some in the bag end of the gearbox (see Figure 11-24, p. 25). Make sure that there is no power! 25. Dismantle the plug for the oil level sensor (see Figure 11-23, p. 25). 26. Dismantle the heating elements in the bag end of the gearbox (see Figure 11-23, p. 25). Make sure that there is no power! 27. Dismantle the cable tray and cables in the bag end of the gearbox (see Figure 11-23, p. 25).

Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.vestas.com

: 1001816. PT 100. V82 – 1.vestas.65 MW Procedure Date 2007-07-23 Class: II Page 25 of 62 3 1 2 4 Figure 11-23: 1 2 Heating element PT 100 sensor Heating elements.Item no.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.com . and cable tray 3 4 Cable tray Oil level sensor Figure 11-24: Wiring to one of the heating elements in gearbox Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.

NOTE Oil will drip out when dismantling the hoses. Mount a ratchet lever hoist in the big generator lifting eye and to the strap (see Figure 11-27. Figure 11-25: Gear oil hose blanked off.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. NOTE Use straps. Dismantle the oil pump from the base frame and move it as much as possible back against the generator (see Figure 11-29. service crane. V82 – 1. Put a strap between the pump. 27).com . p. Loosen the SAE flanges on the pump and turn the two hoses a bit up. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. 28). 28). NOTE Suction hose is placed on the bottom of the gearbox and pressure hose at the left side of the gearbox. 26).vestas.Item no. Place a waste tray or a bucket under the hose fittings and blank off the hoses with plugs or twisted rags with a plastic bag around tied up with a cable tie (see Figure 11-25. p. 29. p. p.: 1001816. Dismantle the gear oil hoses (70mm fork spanner) (see note below) and the off line filter hoses (if the turbine is equipped with an off-line filter). and a small ratchet lever hoist to lift the oil pump. and the service crane. in order not to have the pump standing on the hoses on the bottom of the nacelle floor (see Figure 11-26.65 MW Procedure Date 2007-07-23 Class: II Page 26 of 62 28.

: 1001816.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.vestas.65 MW Procedure Date 2007-07-23 Class: II Page 27 of 62 1 2 2 Figure 11-26: 1 Lifting strap Gear oil pump 2 SAE flanges Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.com .Item no. V82 – 1.

vestas. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.: 1001816.65 MW Procedure Date 2007-07-23 Class: II Page 28 of 62 Figure 11-27: Lifting the oil pump Figure 11-28: Lifting point for ratchet lever hoist Figure 11-29: Gear oil pump drawn back against the generator.Item no. V82 – 1.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.com .

3 2 1 5 4 Figure 11-30: 1 2 3 Safety disconnectors for the slip ring unit Plastic cover Grille Slip ring unit 4 Cables with plugs* to the slip ring unit * In some turbines there are no plugs. 31.Item no. Bracket for rotating union and shielding 5 Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.6 Slip Ring Unit and Rotating Union 30. Dismantle the plugs / cables to the slip ring unit and the two safety disconnectors on the gearbox and place them away in a safe place (see Figure 11-30. 29). 34.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. The wires have to be screwed off in the slip ring unit. p. Dismantle the grille “3” and the bracket “5” (see Figure 11-30. Switch off the power to the slip ring unit (see Figure 11-30. 29). p. p. p.65 MW Procedure Date 2007-07-23 Class: II Page 29 of 62 11.com . p.: 1001816. Remove the plastic cover over the slip ring unit and measure with a Fluke Multi meter. V82 – 1. 31). NOTE The hoses and pipes must be blanked off or closed with a plastic bag secured with cable ties. 33. 29).vestas. that the power is off (see Figure 11-31. 30). 32. Dismantle the rotating union and hoses (see Figure 11-33.

36. Dismantle the slip ring unit. Electric shock Risk of death or severe injury when touching wires with power. Switch off power and check with a voltmeter that there is no power supply to the wires.Item no. Use Live working gloves!! (not gloves as in the picture !) Figure 11-32: Dismantling the pipe holders 37.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.65 MW Procedure Date 2007-07-23 Class: II Page 30 of 62 35. Dismantle the wires going into the hub.com .: 1001816. V82 – 1. 30). p. Dismantle the pipe holders (see Figure 11-32. Figure 11-31: Check that the power is off. NOTE Note down how the wires are placed. for correct remounting. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Do not touch wires unless you are sure that the power supply is off.vestas.

p.7 Rotor Lock 38.com .: 1001816.vestas.65 MW Procedure Date 2007-07-23 Class: II Page 31 of 62 Figure 11-33: Rotating union 11. V82 – 1. the two cut off pieces must be mounted again with aluminium plates and be put on with pop rivets and sealant. Cut out the necessary piece of the nacelle cover to get room for the rotor lock.Item no. 32). p. Afterwards.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. 32) (see Figure 11-35. and finally painted (see Figure 11-34.

65 MW Procedure Date 2007-07-23 Class: II Page 32 of 62 Figure 11-34: Make a cut out in the nacelle cover with a bayonet saw Figure 11-35: Cut out following the yellow line in this figure 39.: 1001816.vestas. Position the rotor with 2 blades up (“bunny ears”).R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.com . Check through the hatch that it is positioned correctly. V82 – 1.Item no. so that the yellow rotor hooking point is pointing up. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.

NOTE If it is impossible to loosen the bolts.: 1001816. Loosen and dismantle the 4 M60 stud bolts for the main bearing pedestal. 34). dismantle the following 8 bolts. Mount the nut again and screw in the M12 bolts in the stud. 43.5 mm holes in the stud and make a M12 thread. Turn the rotor back to “bunny ears” / V position. position with the yellow hooking point upwards. Dismantle the necessary bolts on the main shaft/hub connection to mount the rotor lock flange pieces (55mm socket): Counting from the upper middle bolt and 4 bolts down. drill 11. take it off. It may be necessary to mount two nuts counter tightened with two 90mm impact wrenches or even with the Hytorc and the MXT 3 (see Figure 11-37. 34). p.vestas. V82 – 1. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Loosen and dismantle the 4 M60 nuts and washers on the main bearing pedestal (90 mm socket). Turn the rotor for access and mount the first flange piece.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. Do the same in the other side for mounting the other flange piece. 42. p. so there are 9 bolts between the 2 flange pieces. mark up through the M12 holes.65 MW Procedure Date 2007-07-23 Class: II Page 33 of 62 40.Item no. Then mount the nut. make a special tool of a M60 nut with a 10mm plate welded on with two M12 holes in it. Then you are able to loosen the stud bolt (see Figure 11-38. Figure 11-36: Rotor lock flange piece mounted 41.com .

com .vestas. V82 – 1.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.: 1001816.65 MW Procedure Date 2007-07-23 Class: II Page 34 of 62 Figure 11-37: Loosening the stud bolts.Item no. Figure 11-38: Special nut for dismantling the stud bolts Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.

Item no. Mount the new long stud bolts. Mount the rotor lock pins (see Figure 11-40. V82 – 1.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.65 MW Procedure Date 2007-07-23 Class: II Page 35 of 62 44. 36). 46. Mount the rotor lock frames.vestas. and screw them down so that 50mm thread is sticking up.: 1001816. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Tighten them up with the hytorc and the MXT3 or MXT10 to 2000Nm. Mount the M60 nuts and new washers. They must turn with the thread holes in the ends to the back. 1 2 3 Figure 11-39: 1 2 3 Right rotor lock Rotor lock frame.com . 47. right hand side Lock pin Thread holes in the end of the frame 45. p.

Item no. V82 – 1.: 1001816. 48. p. Dismount the bolts going through the brake disc to the distance tube for the coupling (See Figure 11-41.com . 37). Mount the lock pin in the brake disc.65 MW Procedure Date 2007-07-23 Class: II Page 36 of 62 Figure 11-40: Mounting the rotor lock pins NOTE When the first lock pin is inserted. 50.8 Centa Link Coupling 49.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.vestas. turn the rotor a little bit to centre the other flange piece and the lock frame before inserting the other lock pin. Lock the lock pins with the bolts in the end of the blocks and with the pins going through the block and lock pins 11. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.

52. Dismantle the bolts from the distance tube to the rubber element. V82 – 1. 54.: 1001816. p.65 MW Procedure Date 2007-07-23 Class: II Page 37 of 62 Figure 11-41: Brake disc at gearbox side 51. p. Use a service crane to hold the element. Take down the distance tube. One can also hang the crane up in a long strap fastened at the cooler arrangement on the roof or on one of the rails (see Figure 11-43. 38).R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.Item no.vestas. Make room for this by lifting the element in over the generator shrink disc temporary. 53. 38).com . The service crane is hung up in a strap in the skylight around a big torque wrench key or similar. Lift down the coupling element. Dismantle the link arms (see Figure 11-42.

vestas.Item no.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.: 1001816.com . V82 – 1.65 MW Procedure Date 2007-07-23 Class: II Page 38 of 62 3 2 4 5 1 Figure 11-42: 1 2 3 Coupling with Centa link element 4 5 Generator shrink disc Distance tube Lock Pin Rubber element Link Arm Figure 11-43: Service crane to lift the coupling Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.

com . In some of the turbines (twin speed) there is not much room to get the gearbox out. NOTE When mounting the coupling again. mount the distance tube to the brake disc. to prevent it from falling out of the nacelle. because they are balanced together.Item no. all the link elements must be replaced at the same time. and plug up the block and pipes with blind plugs or small rags Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Dismount the pipes at the pitch distributor block.: 1001816.vestas. Mount the link elements first at the generator.10 Preparation in the Hub 57. Mark the generator shrink disc inner and outer elements to be sure to be able to mount it correctly again. 58. first in the sides and bottom. therefore the generator has to be pushed backwards as far as possible. NOTE Secure the generator with bolts. 11.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. Dismantle it by manoeuvring it out with a crowbar when the bolts are dismantled. Lift the element in place and tighten it to the distance tube. 11. V82 – 1. Loosen the generator and push it with the hydraulic jacks from the fixture.65 MW Procedure Date 2007-07-23 Class: II Page 39 of 62 55.9 Moving the Generator 56. Never do it in the top. then at the coupling. lift the element up over the generator shrink disc. NOTE If a link element is damaged and has to be replaced. Relief the hydraulic pressure in the hub on the 4 needle valves for the pitch.

vestas.Item no. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.com . Mount a little ratchet lever hoist around the distributor block to lift it away (see Figure 11-45.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. 41).: 1001816. V82 – 1.65 MW Procedure Date 2007-07-23 Class: II Page 40 of 62 3 2 1 Figure 11-44: 1 2 Pipes to be dismantled Pitch distributor block Hub 3 Hub controller 59. p.

: 1001816.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. V82 – 1. 1 Figure 11-46: 1 Distributor block dismantled Saw off the plate as shown with the red dotted line. 41). Dismantle the distributor block and put a plastic bag around it.vestas.Item no. Let it hang in the ratchet lever hoist (see Figure 11-45. p. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.65 MW Procedure Date 2007-07-23 Class: II Page 41 of 62 Figure 11-45: Ratchet lever hoist to lift the distributor block 60.com . in order to prevent oil from dripping out.

p.65 MW Procedure Date 2007-07-23 Class: II Page 42 of 62 61. 41). Dismantle the other hoses which will be necessary for lifting off the nacelle cover and blank them off with blanking plugs or with rags and plastic bags. p. to get room for pulling out the pitch pipe in the hub (see Figure 11-45.: 1001816. Mount hose clamps on the two cooling water hoses as shown in the picture (see Figure 11-48.com .11 Hoses to the Coolers on the Roof 63. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.Item no. 65. V82 – 1. Pull out the pitch pipes in the hub and at the same time another service technician is guiding it in from the gearbox back (communicating by walkie talkies).vestas. 41). Use a bayonet saw to saw off plate behind the distributor block as shown in the picture.(see Figure 11-46. Make sure that there is no pressure in the cooling water system. p. 64. 1 Figure 11-47: 1 Pitch pipes drawn out in the hub Plate sawn of here 11. 62. 43).R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.

V82 – 1. Loosen and dismantle the water hose under the water pump and hold a bucket underneath to collect approx.Item no. 5L of coolant. Figure 11-49: Hose at water pump Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.: 1001816.65 MW Procedure Date 2007-07-23 Class: II Page 43 of 62 Figure 11-48: Hose clamps mounted 66.vestas.com .

Dismantle the right rear fluorescent lamp and the necessary cables. Disconnect W541 and W543 switches in the top controller. Dismantle the wires at the ice sensors (see Figure 11-51.Item no.com .65 MW Procedure Date 2007-07-23 Class: II Page 44 of 62 11. Figure 11-50: Dismantled cables / wires 68. 45).vestas. 71.: 1001816.12 Cables and Wires 67. 70. p. Dismantle the wires at the US sensor.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. V82 – 1. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Dismantle the wires at the aviation light. 69.

Loosen the bolts one by one a little at the time as described above in point 72. Loosen the bolts in the shrink disc in the following way: Loosen the bolts one by one ¼-½ revolutions at a time (3-5 times on the Hytorc). A service technician on each side of the shrink disc with a Hytorc each (50mm sockets). V82 – 1. Breaking bolts If a shrink disc bolt is loosened entirely one at a time.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. It is advantageous that two service technicians carry out the work.com . Keep your body away from the bolts.65 MW Procedure Date 2007-07-23 Class: II Page 45 of 62 Figure 11-51: Ice sensors 11.13 Shrink Disc 72.: 1001816. the big tension on this bolt will cause it to break and be shot out like a missile.vestas.Item no. NOTE Make sure that the shrink disc is totally loosened and there is no more tension inside the shrink disc! Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.

Figure 11-53: Plug Figure 11-54: Warming up one of the plugs Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. 73.Item no. p. V82 – 1.vestas.: 1001816. 46) (see Figure 11-55. Warm up the two plugs (one in each side of the shrink disc) for the thread rods with a torch and dismantle them with a proper chisel and a wrench (see Figure 11-54. 47).com . 74. p.65 MW Procedure Date 2007-07-23 Class: II Page 46 of 62 Figure 11-52: Loosening shrink disc bolts NOTE The next 3 steps can be carried out when the nacelle cover has been dismantled and the mobile crane has lifted up the small torch set.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. 47). Tap the threads with a 27mm or 30mm tap. depending of the shrink disc model (see Figure 11-56. p.

Figure 11-57: 27 mm bolt or 30mm bolt / threaded rod is screwed in Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Screw in a bolt or a threaded rod with a nut welded on.Item no. Figure 11-56: Thread is tapped.vestas. V82 – 1.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.com .65 MW Procedure Date 2007-07-23 Class: II Page 47 of 62 Figure 11-55: Plug is screwed out. 75. that the shrink disc is completely loosened.: 1001816. The bolts are screwed in to secure. or as shown in the picture with a counter nut.

upper parts of the rear torque arms and stay bolts. In older models. p. Loosen and remove the stops on the rubber bushings 77. Do the following with these types of torque arms: Loosen and remove the stops on the torque arm bushings (see Figure 11-59. Use a Hytorc to loosen it enough before using an electric impact wrench. p. 48) (see Figure 11-60. V82 – 1.14 Torque Arms 76.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. 48).65 MW Procedure Date 2007-07-23 Class: II Page 48 of 62 11. NM72 or NM82 the torque arms are in one piece. It is not necessary to remove the upper parts on those.vestas.Item no. Loosen and remove the nuts.: 1001816. NM64. Figure 11-58: Torque arm 78.com . Figure 11-59: Stop on bushing Figure 11-60: Stop on bushing Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Only loosen the front torque arms.

: 1001816.Item no. 50). 49). 49).R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.vestas.com . Loosen the stay bolts with a hytorc (hydraulic wrench) just enough to screw it completely off with an electrical impact wrench (see Figure 11-61. p. Mount lock nuts on the stay bolts in order to loosen the whole stay bolt (see Figure 11-61.15 Nacelle Cover 81. p. V82 – 1.65 MW Procedure Date 2007-07-23 Class: II Page 49 of 62 79. Figure 11-61: Loosening torque arm Figure 11-62: Torque arm (old models) 11. p. Dismantle the bolts for the upper part of nacelle cover (nacelle roof) (see Figure 11-63. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. 80.

R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.65 MW Procedure Date 2007-07-23 Class: II Page 50 of 62 Figure 11-63: Dismantle the bolts for the nacelle cover 82. V82 – 1.com . 51). It can be done before or after lifting off the nacelle cover / roof (see Figure 11-65. p.vestas. Mount the safety rail in the nacelle. Figure 11-64: Bolt to be dismantled 83. Dismantle the bolts in the edges.: 1001816.Item no.

Use only lifting equipment designed for the task.g. Hook on the lifting yoke for the nacelle cover. Never stand under a suspended load.com .65 MW Procedure Date 2007-07-23 Class: II Page 51 of 62 Figure 11-65: Safety railing mounted Crushing by falling load Danger to life due to a falling load if e.: 1001816. use only original parts authorised by Vestas. Figure 11-66: Lifting the nacelle cover in the radiators Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. a lifting chain brakes.Item no. 84. Always wear safety helmets with chain straps when the overhead crane is in operation. If replacing spare parts for lifting equipment.vestas.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. V82 – 1.

Item no. It is necessary to use crowbars and knives to help releasing the roof where it is stock in the Sikaflex. V82 – 1.vestas. Let the crane lift the roof free and down.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. Figure 11-67: Releasing the nacelle cover Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Start releasing from the middle of the nacelle and move forward.: 1001816.com .65 MW Procedure Date 2007-07-23 Class: II Page 52 of 62 85.

V82 – 1.65 MW Procedure Date 2007-07-23 Class: II Page 53 of 62 Figure 11-68: Lifting yoke for nacelle cover NOTE For more information.65MW 11. Never work without being hooked or without a safety rail. Make sure to have that the approved safety rail mounted.Item no. see WKI 1001821: Dismantling and lifting Nacelle Cover V82-1.16 Mounting the Main Shaft Fixture Falling to the ground from the nacelle Danger to life due to the risk of falling out of the nacelle while working with the upper nacelle cover / roof dismantled.vestas.com .R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture.: 1001816. Make sure to be hooked onto one or two safe hooking points with two tackle ropes. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.

Item no. The distance blocks come with the fixture (see Figure 11-71.65 MW Procedure Date 2007-07-23 Class: II Page 54 of 62 86. NOTE On some turbines it is necessary to put a distance block between the base frame and the fixture to get it mounted properly.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. V82 – 1. 54) 87.: 1001816. 55). loosen the bolts for the lower parts of the fixture body from beneath and turn the two parts out 90° (see Figure 11-70.vestas. p. Make sure that the right top and side and bottom distance blocks are mounted. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Turn the lower parts in under the main shaft and tighten it together with the upper part loosely. p. Figure 11-69: Loosening bolts Figure 11-70: Lower parts turned out 88. When the crane has lifted up the fixture.com .

55).R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. first the bolts no. 4 (see Figure 11-71. V82 – 1. 91. 1. p. 90.vestas. then bolts no. p. 2 and then bolts no. Hook the lifting equipment onto the gearbox and lift up the gearbox and main shaft with fixture a little just until the gearbox is clear of the base frame (otherwise it can not get out). Tighten the four bolts in the sides for sideways fixation and support against the base frame (see Figure 11-73. Tighten the bolts for the fixture properly. 56).Item no.com .65 MW Procedure Date 2007-07-23 Class: II Page 55 of 62 3 1 5 2 4 Figure 11-71: 1 2 3 Bolts that must be tightened 4 5 Bolts for the bottom distance blocks Distance block is to be mounted here on some turbines To be tightened from beneath Can be tightened from above Vertical adjustment screw 89.: 1001816. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.

Do not stand behind the gearbox.vestas. Getting squeezed between gearbox and generator If a person stands between the gearbox and generator when the gearbox is lifted out. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.Item no. p.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. Let the crane hold the weight of the gearbox 93.: 1001816. (see Figure 11-74. 57). Stand in the side of the nacelle. V82 – 1.65 MW Procedure Date 2007-07-23 Class: II Page 56 of 62 Figure 11-72: Fixture seen from below Figure 11-73: Bolt for sideways adjustment fixation (seen from above) 92. Push the gearbox off with the pusher system against the main bearing pedestal nice and easy. the gearbox can swing bag against the generator and squeeze the person standing there. Let the crane follow the movement.com .

com .R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. When it is clear of the main shaft.65 MW Procedure Date 2007-07-23 Class: II Page 57 of 62 Figure 11-74: The Pusher system 94. V82 – 1.vestas.Item no.: 1001816. tighten a couple of bolts in each side of the shrink disc to secure it from falling off. the crane can lift it out of the nacelle and down to the ground. base frame and generator. NOTE Before the gearbox is out of the nacelle. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.

17 Preparing the New Gearbox 95. NOTE The shrink disc must go straight on.65 MW Procedure Date 2007-07-23 Class: II Page 58 of 62 11. rags and possibly Scotch Brite 3M.com . 96. Clean the rust protected surfaces with benzine. If the new gearbox comes without a shrink disc. 59).vestas. V82 – 1.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. p. Use the special lifting tool for this (see Figure 11-76. otherwise it is impossible to mount it! Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Figure 11-75: Cleaning the shafts and the contact faces.: 1001816. swap the shrink disc over from the old gearbox.Item no.

98.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. V82 – 1.: 1001816.com .65 MW Procedure Date 2007-07-23 Class: II Page 59 of 62 Figure 11-76: Shrink disc being mounted 97. Mount the shrink element for the brake disc and the brake disc if the new gearbox is not with premounted brake disc.vestas. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Tighten to the right torque setting according to I&S data. Mount the anchor plate with the brake calibre arrangement.Item no.

com .65 MW Procedure Date 2007-07-23 Class: II Page 60 of 62 Figure 11-77: Brake calibre arrangement is mounted.: 1001816.Item no. Figure 11-78: Warming up the hollow shaft Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www.vestas.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. V82 – 1.

104. the stop plates and the upper parts.: 1001816. and check with a digital spirit level that the gearbox is hanging in the right angle. Torque tighten the torque arms to the specified setting in the I&S data. V82 – 1. Warm up the hollow shaft evenly all over with a gas burner for at least half an hour (see Figure 11-78. Lift the gearbox to the nacelle and guide it carefully over the main shaft and draw it into place with two ratchet lever hoists mounted via straps in the eyes on the main bearing pedestal and around the torque arms. adjust it. If the brake disc is hard to turn. p. Figure 11-79: Drawing the new gearbox in place with two ratchet lever hoists 103.vestas. 61). p. 11. 60). Loosen the fixture and lift it down. Dismantle the lifting equipment from the gearbox.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. it is because of an oblique angle (see Figure 11-79.18 Switching Gearboxes 101.Item no.com . If not. Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Let the crane lift the new gearbox from the ground. 102. 106. It is crucial.65 MW Procedure Date 2007-07-23 Class: II Page 61 of 62 99. Tighten loosely by hand. 105. 100. to draw evenly in both lever hoists and at the same time be rotating the brake disc. Let the gearbox rest on the torque arms and mount the rubber bushings. Mount the lifting equipment for the gearbox.

12. See label: 1500 Nm Take 4 bolts in each side of the element. Check Points Before starting up the turbine. See instruction in Service and Maintenance Manual.g. then up to eight in each side and so on until all the bolts have been tightened.19 107. Use the MXT3 or the MXT10 if the MX3 can not do the work. 12 111. 15 115. 10. 12. 12. 11. V82 – 1.9. Reinstalling the Nacelle and Hub Components Reinstall the nacelle components in the reverse order.: 1001816. M33.9. 108.1-720. M33.9. 10. Dismantling the Rotor Lock Dismantle the rotor lock when it is possible to have the brake activated. Alignment of Gearbox and Generator Check the alignment of the generator and adjust it if necessary. M30. 13 113.65 MW Reinstalling the Nacelle and Hub Components Date 2007-07-23 Class: II Page 62 of 62 11.R3 Issued by: Technology Type: Work Instruction Replacement of Gearbox with Fixture. See label: 1985 Nm TAS 317.: in the hollow shaft. check that all the points in the check list 1001818 that are possible to do before start-up have been carried out.1 112. Preparation of the Old Gearbox The old gearbox must be rust protected with Eli sol or a similar product on all bare surfaces (E. 16 116. torque arm surface).9. – – – – Tightening the Shrink Disc Tighten the shrink disc to the specified torque setting depending on the kind of element: MSD 720-81-1. Start up During start-up. 109. Take off the lifting equipment from the nacelle roof and let the crane go down. 14 114.20 110. See label: 2650 Nm MSD 720-22-7. Installing the Nacelle Cover Lift the nacelle cover up and secure it with bolts in both ends and sides of the nacelle. check the remaining points in the IRF: 1001818 Vestas Wind Systems A/S · Alsvej 21 · 8900 Randers · Denmark · www. Tighten all the bolts and seal the nacelle cover with Sikaflex or similar where it was sealed before.Item no.com .vestas. See label: 2150 NM FSD 720. M33.