REpower Systems SE.

Maintenance Specification 5M Platform Date 2012 02 14

X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1. General checks
1.1 x ● visual check of whole turbine visual check for technical particularities, even if not explicitly pointed out, take photos if necessary and inform master
service technician, refer to TO 043!
In case of cracks/damages to the supporting structure, shut down wind turbine and inform manufacturer's service.
In case of corrosion, fix damages without delay as per specification "Corrosion protection & protective coating system".

1.2 x ● Leaks, water ingress Determine causes, dry affected areas and seal (trim panels, switch cabinets)
1.3 ● anchor points / safety rope system for - visual check for corrosion, wear marks and other defects
personal security - check surrounding structure for cracks and other signs of structural failure
ATTENTION: after a fall the anchor point must not be used anymore until it was checked and released for use by a
qualified person. Mark anchor point accordingly!

2. Rotor blades LM
2.1 x ● Blade surface, blade tip, receptor With binoculars check surface for: 1st blade number: Condition:
1. Traces of smoke
Inspection of the specified points with 2. Flaking, voids
binoculars depends to a great extent 3. General condition
upon weather conditions, and it may thus 4. Erosion 2nd blade number: Condition:
be impossible to detect defects under 5. Condition of erosion protection film
certain circumstances. 6. Contamination
Strike any point which cannot be 7. Cracks
checked! Please specify your reason! 8. Installation of rain deflector
In case of damages follow TO 083! 9. unusual noises during operation 3rd blade number: Condition:
In case of blade inspection via rope
access observe SI/SA 018!

2.2 x ● Check for correct seating, fracture, corrosion

(laminated components must not be checked: receptors, cables, lightning protection ring)
● Visually inspect the brushes and spark gaps.
check of lightning protection system
Replace brush if residual length is ≤ 7 mm!
Check contact surfaxce, spring force and correct seating.

2.3 x ● Cover, blade interior Inspect for secure mounting, open the lid, visual inspection of blade interior, remove loose parts / contamination. In case
of any damages observe TO 072!
Inspect trimming weights (if fitted) for secure mounting. In case of loose trimming weights inform REpower service.

2.4 x ● Lightning counter cards replace 3x lightning counter cards

3. Rotor blade anchors
3.1 x All (3x128) Stud M36 10.9 / dry and Delta Tone, 472kN with hydr. tensioning 55 S
collar nut Delta Seal cyl.
Rotor blade LM 61.5 P / P2
● 3 x 12 of 128 Stud M36 10.9 / dry and Delta Tone, 400kN with hydr. tensioning 55 S
collar nut Delta Seal cyl.

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
4. General checks
Blade bearings
4.1 x ● Condition cover blade bearing and seals Visual inspection of cover and seals for cracks, porosity, tight mounting and leaks, clean if necessary
4.2 x ● Condition blade bearing gearing - check surface of 0° gearing area for attrition
- check for wear debris in used grease
- check for raptures and corrosion
- check fixing bolts of pitch gearbox output acc. To TO 054
- while turning the blade check for unusual sounds

4.3 x All (3x120) M36-10.9 MoS 2 2500Nm 55 S

● 3x blade bearing - rotor hub visual inspection of all bolted connections in the blade bearing for tightness, inspection of all seals for increased leakage
of grease.
4.4 x ● Grease Consumption: If grease consumption varies, check operation of pump for self-lubrication
Fuchs Lubritech approx 6.7 l /year system. If grease consumption is too low also check whether red pin is visible
"gleitmo 585K" (incl. gearing on the pressure valve, in this case the grease line is blocked. If necessary
Self-lubrication system tracks / gearing capacity) replace disposal container. Check whether self-lubrication system fully coats the
teeth in the adjustment area (0 - 90°), otherwise see point on checking pump.
Manually re-lubricate remaining area (90 - 360°) as required for corrosion
protection
4.5 x ● grease disposal bottles check and replace if necessary
5. Pitch system
in case of 2 oil reservoirs
5.1 per wind farm in turbine with the lowest turbine number:
x ● 1st to 3rd year:
use only oil jars of analysing laboratory, rinse before taking sample, mark bottled sample, care for cleanliness during and
Take oil sample for oil analysis
after the sample taking
Complete accompanying ticket for oil sample!

5.2 ● Oil level check, pitch gears Place gears in vertical position. Pinion pointing downward. Oil level must be in mid position of oil level control
planetary stage
5.3 ● Oil level check, pitch gears, spur gear Place gears in vertical position. Pinion pointing downward. Oil level must be in mid position of oil level indicator
stage
in case of 1 oil reservoir
5.5 per wind farm in turbine with the lowest turbine number:
x ● 1st to 3rd year:
Take oil sample for oil analysis use only oil jars of analysing laboratory, rinse before taking sample, mark bottled sample, care for cleanliness during and
after the sample taking
Complete accompanying ticket for oil sample!

5.7 ● grease lubrication of blade pitch Klüber Plex BEM 3 ponts: bearings of output and input shaft, electr. motor
gearboxes 41-132
5.8 x ● Function of 95° limit switch Activate manually, evaluate status in the control, check for tight seating of switches, clean if necessary

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
6. General
Rotor checks
hub
6.1 x All (3x30) M20-10.9 MoS 2 420Nm 30 S
3x blade pitch gearbox - rotor hub
● Visually inspect and check the tightness of all screws in the joint
6.2 x All (3x8) M16-8.8 Dry 200Nm 24 S
3x blade pitch gearbox - pitch motor
● Visually inspect and check the tightness of all screws in the joint
6.3 x All (3x8) M16-8.8 Dry 200Nm 24 S
3x rechargeable battery box
● Visually inspect and check the tightness of all screws in the joint
6.4 x All (3x8) M16-8.8 Dry 200Nm 24 S
3x converter box
● Visually inspect and check the tightness of all screws in the joint
6.5 x All (8) M16-8.8 Dry 200Nm 24 S
1x central box
● Visually inspect and check the tightness of all screws in the joint
6.6 x All (4) M10-8.8 Dry 80Nm 17 S
1x measuring box
● Visually inspect and check the tightness of all screws in the joint
6.7 x All (4) M8-8.8 Dry 50Nm 13 S
1x blade box
● Visually inspect and check the tightness of all screws in the joint
6.8 x All (8) M16-8.8 Dry 200Nm 24 S
1x frame blade box, measuring box
● Visually inspect and check the tightness of all screws in the joint
6.9 x All (64) M16-8.8 Dry 200Nm 24 S
Box frame complete
● Visually inspect and check the tightness of all screws in the joint
6.10 x All (3x2) M36-8.8 Dry 2300Nm 55 S
3x cross beam lubrication blade bearings
● Visually inspect and check the tightness of all screws in the joint
6.11 x All (3x2) M20-8.8 Dry 400Nm 30 S
3x blade limit switch
● Visually inspect and check the tightness of all screws in the joint
6.12 x All (3x4) M36-8.8 Dry 2300Nm 55 S
● Elastomer bearing axle cabinet frame Visually inspect and check the tightness of all screws in the joint
Visually inspect for cracks and damages of the elastomer bearings
6.13 x All (6x3) M36-8.8 Dry 2300Nm 55 S
Spinner retainer - rotor hub
● Visually inspect and check the tightness of all screws in the joint
6.14 x All (6x6) M20-8.8 Dry 400Nm 30 S
Spinner retainer - spinner
● Visually inspect and check the tightness of all screws in the joint

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
6.15 x General checks All (3x20) M20-8.8 Dry 400Nm 30 S
Spinner retainer
● Visually inspect and check the tightness of all screws in the joint
6.16 x All (6x2) M36-8.8 Dry 2300Nm 55 S
Spinner retainer
● Visually inspect and check the tightness of all screws in the joint
6.17 x All (6x19) M 16-8.8 Dry 200 Nm 24 S
Spinner segments
● Visually inspect and check the tightness of all screws in the joint
6.18 x All (3x24) M20-8.8 Dry 200Nm 30 S
Blade bearing cover - hub
● Visually inspect and check the tightness of all screws in the joint
6.19 x All (4x2) M20-8.8 Dry 200Nm 30 S
Blade bearing cover - segments
● Visually inspect and check the tightness of all screws in the joint
6.20 x All (78) M39-10.9 MoS 2 3300Nm 60 S
Rotor hub - rotor shaft
● Visually inspect and check the tightness of all screws in the joint
7. Rotor bearing
7.1 x ● Empty grease trays Visually inspect grease that has escaped. Attention: correctly dispose of grease that has escaped
7.2 x ● Consumption: If grease consumption varies, check operation of top-up quantity:
approx. 12.2l / year pump. If grease consumption is too low also check
Grease Fuchs
whether red pin is visible on the pressure valve, in
Self-lubrication system, rotor bearing Lubritech "Stabyl
this case the grease line is blocked.
EOS E2"
If necessary, top up grease.

7.3 x ● speed sensor rotor shaft Check for clearance (2 to 2.5 mm) and function, remove discharged grease if necessary
7.4 x All (20) M42 -10.9 dry 966kN with hydr. tensioning 65 S
Front pedestal bearing (movable bearing)
cyl.
- main frame
● Visually inspect and check the tightness of all screws in the joint
7.5 x Front pedestal bearing (movable bearing) All (2 x 18) M30-10.9 MoS 2 1450Nm 46 S
● - bearing cover Visually inspect and check the tightness of all screws in the joint
7.6 x Front pedestal bearing (movable bearing) All (18) M12-8.8 MoS 2 70Nm 18 / 19 S
● - bearing cover, split Visually inspect and check the tightness of all screws in the joint
7.7 x All (24) M42-10.9 dry 966kN with hydr. tensioning 65 S
Rear pedestal bearing (fixed bearing) -
cyl.
main frame
● visual and tightness inspections of all screw connections in the joint.
7.8 x Rear pedestal bearing (fixed bearing) - All (30) M30-10.9 MoS 2 1450Nm 46 S
● bearing cover, front Visually inspect and check the tightness of all screws in the joint
7.9 x All (12) M30-10.9 MoS 2 1450Nm 46 S
x only All (30) M30-10.9 MoS 2 1450Nm 46 S
Rear pedestal bearing (fixed bearing) -
Brunsbüttel
bearing cover, rear
"Hugo"
● Visually inspect and check the tightness of all screws in the joint
7.10 x ● Check of shaftnuts 2 ANN-0034/ANN- marks have to align
0035

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
8. General
Rotor checks
lock
8.1 Attention: rotor locking must not be activated!
x All (2 x 12) M48-10.9 dry 945kN with hydr. tensioning 60 S
Locking cylinder blocks
cyl.
● visual and tightness inspections of all screw connections in the joint.
8.2 x All (34) M48-10.9 dry 1210kN with hydr. 60 S
locking disk - rotor shaft inner row of
tensioning cyl.
screws
● Visually inspect and check the tightness of all screws in the joint
8.3 x All (42) M48-10.9 dry 1210kN with hydr. 60 S
locking disk - rotor shaft outer row of
tensioning cyl.
screws
● Visually inspect and check the tightness of all screws in the joint
8.4 x All (56) M39-10.9 dry 966kN with hydr. tensioning 60 S
locking disk - gearbox flange cyl.
● visual and tightness inspections of all screw connections in the joint.
9. Gearbox Winergy PZFB 3680
9.1 x ● Take oil sample for oil analysis use only oil jars of analysing laboratory, rinse before taking sample, mark bottled sample, care for cleanliness during and
after the sample taking. Complete accompanying ticket for oil sample! Top up!
9.3 x ● Rubber cuff on the torque arm Check for cracks, delamination and attrition, deformation
9.4 x ● Grounding Check for correct seating of grounding
9.5 x All (2 x 2 x 24) M24-10.9 MoS 2 730Nm 36 S
Torque arm
● Visually inspect and check the tightness of all screws in the joint
9.6 x ● oil cooling Visual inspection for correct mounting and damage, in particular condition of oil hoses (damage or abrasion of hose jacket
and connections). Check function of cooling.
All visible debris on the oil cooler plates must be removed by means of a hand brush or vacuum cleaner!
9.8 x ● Condition of hoses of gearbox Visually inspect for fastening, damage, in particular check condition of hoses (damage / wear of the hose covering and the
Condition of pipes and fittings hose fastening) Replace if necessary
9.9 x ● Fans oil cooler Check function and condition of fans
9.10 x ● Maintenance log Complete manufacturer's maintenance log (delivered with the gearbox).

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
10. General
Slip ringchecks
unit
10.1 ● - check plugs, threaded joints and cables for condition and tight seating
● - clean power slip ring with carbon brushes
● residual length brush 1:
residual length brush 2:
residual length brush 3:
residual length brush 4:
- check power carbon brushes for wear and exchange if
necessary. It is recommended to exchange all carbon brushes of residual length brush 5:
slip ring general the brush block. residual length brush 6:
The carbon brushes may not fall below 5 mm. residual length brush 7:
residual length brush 8:
residual length brush 9:
residual length brush 10:
● - check gold spring wire brushes of the signal element for deformation, discolouration and contamination
● - clean slip ring
'- oil with gold contact spray from supplier

11. Rotor holding brake

11.1 x ● Brake disc surface Check for cracks, scoring, fractures
11.2 x ● Minimum brake pad thickness: actual value brake pad 1:
Svendborg BSAK 3000 (incl. backing plate): 27 mm Actual value: actual value brake pad 2:
Check of brake pads
actual value brake pad 3:
actual value brake pad 4:
11.4 x ● Visual inspection of brake caliper Seal systems. Remove lubricant that has escaped and clean installation! If fitted, empty bottle for leak oil.
Check for oil leaks
11.5 x All (2 x 2) M36-10.9 MoS 2 2500Nm 55 S
Brake caliper - gearbox
● Visually inspect and check the tightness of all screws in the joint

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
12. General checks
Clutch
12.1 x ● Condition of the clutch Check for cracks in paint, deformation or fracture of the clutch disks, damage of insulating pipe
12.2 x All (6) M16-8.8 Dry 170Nm 14 I
Clutch hub - sensor disk
● Visually inspect and check the tightness of all screws in the joint.
12.3 x ● clamping set, gearbox side visual check: no gap must be showing!
12.4 x ● Taper sleeve, clamping bolt Visually inspect and check the tightness of all screws in the joint.
in case of exchange: All (6) M18 Loctite 243 1st pass 235Nm 27 S
Taper sleeve, clamping bolt 2nd pass 350Nm
12.5 x ● Taper sleeve, lock screw Visually inspect and check the tightness of all screws in the joint.
in case of exchange: all (6) M18 Loctite 243 235Nm 27 S
taper sleeve, lock screw
12.6 x ● Maintenance of sliding sleeve Only in case of more than 300° rotation, refer to assembly instructions
12.7 x clamping set, generator side All (12) M20-10.9 Dry To lock (480Nm) 30 S
12.8 x ● taper sleeve, clamping bolt Visually inspect and check the tightness of all screws in the joint.
in case of exchange: All (6) M18 Loctite 243 1st pass 235Nm 27 S
taper sleeve, clamping bolt 2nd pass 350Nm
12.9 x ● taper sleeve, lock screw Visually inspect and check the tightness of all screws in the joint.
in case of exchange: All (2 x 6) M18 Loctite 243 235Nm 27 S
taper sleeve, lock screw
12.10 x Brake disc All (24) M24 Dry 650Nm 19 S
● Visually inspect and check the tightness of all screws in the joint.

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
13. General checks
Generator
13.1 x ● - visual inspection of the carbon brush contact surfaces
carbon brushes / brush holder slip ring - Check for wear: write down brush wear, limit = 1/3 of height of new brush, change if necessary (use same brand and
unit type) and grind-in according to directions.
x ● Conditon of slip ring:
slip ring body : K L M E
wearing-in of the slip ring (mm): ____ ____ ____ ____
appearing of working surface: ____ ____ ____ ____
a - working surface with normal appearance, uniform colour: light to dark brown
b - working surface with well pronounced striations and tracks
c - surface scratches in working surface with slight scoring
d - irregularly formed, speckled working surface
e - formation of light spots of various density randomly distributed over the working surface
f - severe burning with oxidised surface
g - other remarks:

13.2 x ● Outer filter / outlet air duct Function check, inspect for damage , unusual noises and soiling
check the fixation of the in- and outlet hoses and the noise reduction material inside the air ducts
13.3 x All (4) M36-8.8 Dry 2300 Nm 55 S
Elastomer bearing at generator base
● Visually inspect and check the tightness of all screws in the joint
13.4 x All (4 x 4) M20-8.8 Dry 400 Nm 30 S
Elastomer bearing at generator carrier
● Visually inspect and check the tightness of all screws in the joint
13.5 x All (8) M24-8.8 MoS 2 Lock to generator 36 S
Generator frame - adjusting screw
● Visually inspect and check the tightness of all screws in the joint
13.6 x Visually inspect and check the tightness of all screws in the joint
check of strain relief of all cables
Power cable rotor
● cable connection +ROT Visually inspect and check the tightness of all screws in the joint
check of strain relief of all cables

13.7 x Visually inspect and check the tightness of all screws in the joint
check of strain relief of all cables
Termination box stator
● earth connection +STA Visually inspect and check the tightness of all screws in the joint
check of strain relief of all cables

13.8 x ● Consumption approx. If grease consumption varies, check operation of top-up quantity:
Grease 5,8 l / year pump. If grease consumption is too low also check
Self-lubrication system generator bearing Klüber "Klüberplex whether red pin is visible on the pressure valve, in
BEM 41-132" this case the grease line is blocked.

13.9 x ● Maintenance log Complete manufacturer's maintenance log (cf. app.).

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
14. General checks
Svendborg hydraulics for rotor holding brake
14.1 ● Take oil sample for oil analysis use only oil jars of analysing laboratory, rinse before taking sample, mark bottled sample, care for cleanliness during and
after the sample taking
Complete accompanying ticket for oil sample!
14.2 x ● Oil level check Oil level must be in the middle of the level gauge. Turbine must not be in operation.
14.5 x ● Check for oil leaks Seal systems. Remove lubricant that has escaped and clean installation!
14.6 x ● Air filter check Visually inspect for external damage
14.8 x ● Condition of hoses Visually inspect for fastening, damage, in particular check condition of hoses (damage / wear on hose coverings and
Condition of pipes and threaded joints hose fixing). Replace if necessary
14.9 x ● Pressure sensor switch on point and Setpoints: actual values:
switch off point Switch on pressure: Pon = 100 bar switch on pressure:
Switch off pressure: Poff = 115 bar switch off pressure:
14.10 x ● setpoint pressure control valve Setpoint: Pos. 16 = 140 bar ± 2 bar actual value:

15. Svendborg hydraulics for yaw brake

15.1 ● Take oil sample for oil analysis use only oil jars of analysing laboratory, rinse before taking sample, mark bottled sample, care for cleanliness during and
after the sample taking
Complete accompanying ticket for oil sample!
15.2 x ● Oil level check Oil level must be in the middle of the level gauge. Turbine must not be in operation.
15.5 x ● Check for oil leaks Seal systems. Remove lubricant that has escaped and clean installation!
15.6 x ● Air filter check Visually inspect for external damage
15.8 x ● Condition of hoses Visually inspect for fastening, damage, in particular check condition of hoses (damage / wear on hose coverings and
Condition of pipes and threaded joints hose fixing). Replace if necessary
15.9 x ● Pressure sensor switch on point and Set points: actual values:
switch off point Switch on pressure: Pon = 160 bar switch on pressure:
Switch off pressure: Poff = 170 bar switch off pressure:

15.10 x ● Pressure, pressure limiting valve Set point: Pos. 16 = 200 bar ± 2 bar Pos. 22.1 = 20 bar actual value:
(residual pressure on following)
16. Hydraulic rotor locking/cabin roof
16.1 ● Take oil sample for oil analysis use only oil jars of analysing laboratory, rinse before taking sample, mark bottled sample, care for cleanliness during and
after the sample taking
Complete accompanying ticket for oil sample!
16.2 x ● Oil level check Oil level must be in the middle of the level gauge. Turbine must not be in operation.
16.5 x ● Check for oil leaks Seal systems. Remove lubricant that has escaped and clean installation!
16.6 x ● Air filter check Visually inspect for external damage
16.8 x ● Condition of hoses Visually inspect for fastening, damage, in particular check condition of hoses (damage / wear on hose coverings and
Condition of pipes and threaded joints hose fixing). Replace if necessary
16.9 x ● Pressure, pressure limiting valve set point: pos. 40 = 150 bar ± 2 bar actual value:

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
16.10 x ● General checks
Pressure sensor switch on point and Set points: actual value:
switch off point Switch on pressure: Pon = 250 bar switch on pressure:
Switch off pressure: Poff = 260 bar switch off pressure:

17. Anemometer/wind vane/obstacle light

17.1 x ● Grounding, weather mast Check for correct seating
17.2 x ● Condition / fastening of anemometer Make sure the axle can be easily moved, check fastening of housing on carrier.
17.3 x ● Condition / fastening of vane visual check, make sure the axle can be easily moved, check fastening of housing on carrier.
17.4 x ● Obstacle lights (if fitted) Function check by means of blacking out the day and night sensors, visual check of cables for brittleness, corrosion
on the plugs, remove soiling (bird droppings) of obstacle light.

18. Yaw brake

18.1 x ● Brake disc surface Check for cracks, scoring, fracture
18.2 ● Svendborg BSAB 120-S-100:
Change brake pads if minimum thickness Minimum brake pad overall thickness:
replace brake pads, once indicator pin is diving into yoke completely
is reached 14mm
(= 2 mm of brake pad thickness)
18.3 x ● Seal systems. Remove lubricant that has escaped and clean system!
Check oil in oil collection bottles If large quantities of oil have accumulated in the leakage-oil collection bottles, replace seals at brake calipers.
Discharged oil must be disposed of properly.
18.4 x All (8x12) M36-10.9 MoS 2 2500Nm 55 S
Yaw brake - main frame
● Visually inspect and check the tightness of all screws in the joint
19. Yaw bearing
19.1 x ● Condition of yaw bearing Visually inspect gearing and seal, clean if necessary
19.2 x ● Grease Consumption approx. If grease consumption varies, check operation of top-up quantity:
Check amount of grease in races / teeth, Fuchs Lubritech 4.4l / year pump. If grease consumption is too low also check
top-up of necessary "gleitmo 585K" (incl. gearing whether red pin is visible on the pressure valve, in
capacity) this case the grease line is blocked.
19.3 x All (120) M39-10.9 MoS 2 3300Nm 60 S
Yaw bearing - main frame
● Visually inspect and check the tightness of all screws in the joint
19.4 x All (120) M39-10.9 MoS 2 3300Nm 60 S
Tower head - yaw bearing
● Visually inspect and check the tightness of all screws in the joint
20. Yaw adjustment
20.2 x ● Oil 1: 2: 3: 4:
Gearbox oil level check and top-up
Mobil "Mobilgear
quantity (where applicable)
SHC XMP 320" 5: 6: 7: 8:

20.4 x ● Yaw gearbox leaks Seal systems is case of oil escape

20.5 x All (8x32) M24-10.9 MoS 2 730Nm 19 I
Yaw gearbox - main frame
● Visually inspect and check the tightness of all screws in the joint
20.6 x ● check gap el. yaw brake Stromag BZFM 10: 0,4 - 0,7 mm
Bonfiglioli FA06: 0,4 - 0,55 mm

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
21. General checks installation in nacelle
Cabling/electrical
21.1 x ● Cracks / damage to the cables Visually inspect: cable laying and visible damage
21.2 x ● Nacelle lighting Check function of nacelle lighting
21.3 x ● grounding switch cabinets Check for correct seating
grounding switch cabinet doors
grounding load beams
22. Tower (general) Benennung /
22.1 x ● Check welded joints Visually inspect, pay attention to paint flaking
22.2 x ● Ladder / rails fastening Check for correct seating and safety in use
22.3 x ● Cables and wires Visually inspect all cables and wires for laying and damage
22.4 x ● Lighting Check function of the lighting, external lighting and emergency lighting
22.5 x ● Various tower groundings Check the groundings for correct seating (tower, door, platforms, tower base, switch cabinet, ladder)
22.6 x all
fixation platforms and rails
● Visually inspect and check all screws in the joint.
22.7 x all M24-10.9 MoS2 680 Nm 41 S
fastening beams of elevator system
● Visually inspect and check all screws in the joint. (ladders req)
wind farm Ormonde (tower hub height 95m)
22.20 x All (110) M64-10.9 MoS2 15000 Nm 95S
Foundation flange
● Visually inspect and check the tightness of all screws in the joint
22.21 x All (116) M48-10.9 MoS2 6500 Nm 80 S
Joint flange
● Visually inspect and check the tightness of all screws in the joint

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
23. General checks
Controller/converter/transformer
23.1 x ● maintenance log converter Maintenance as per manufacturer's instructions, fill out manufacturer's maintenance report (cf. app.).
Attention: Maintenance may only be carried out by trained staff!
23.2 x ● Function of heating / fans converter and Check for function and correct seating, remove dirt if necessary
transformer fans
23.3 x ● Water cooling function of Check for function, leaks, pressure and correct seating
pump/heater/fan-heat exchanger check anti-freeze content
23.4 x ● Rotor power cable: Visually inspect and check the tightness of all screws in the joint
rotor panel +GRF connection check of strain relief of all cables
If necessary, refer to torque list.
23.5 x ● Converter power cable: Visually inspect and check the tightness of all screws in the joint
converter cabinet connection UMA-UMD check of strain relief of all cables
If necessary, refer to torque list.
23.6 x ● Stator power cable: Visually inspect and check the tightness of all screws in the joint
stator panel +GSF cabinet connection check of strain relief of all cables
If necessary, refer to torque list.
23.7 x ● Transformer power cables: Visually inspect and check the tightness of all screws in the joint
Connection 950V, 660V +TRA check of strain relief of all cables
23.8 x ● Auxiliary transformer cables If the marking lines shifted against each other over pins and connection, control of the torques is necessary.
connection 660V, 400V +STR If necessary, refer to torque list.
23.9 x ● power cables low voltage distribution Visually inspect and check the tightness of all screws in the joint
board check of strain relief of all cables
connection low voltage distribution board If necessary, refer to torque list.
+NSV
23.10 x ● power cables TSF-panel Visually inspect and check the tightness of all screws in the joint
connection +TSF-panel check of strain relief of all cables
If necessary, refer to torque list.
23.11 ● all panel, transformer Visually inspect and check the tightness of all screws in the joint
check of all earth connections check of strain relief of all cables
If necessary, refer to torque list.
23.12 x ● Maintenance log transformer Complete manufacturer's maintenance log (cf. app.). Signed maintenance log has to be returned to manufacturer.
23.13 x ● ups general check condition of electrical installations, operation and calibration of rectifier / inverter, operation of the static switch,
load data, conditon of alarm and monitoring installation, operation of installed accessories
23.14 x ● Maintenance log ups complete manufacturer's maintenance log (cf. app.). Signed maintenance log has to be returned to manufacturer.

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
24. General checks
Safety functions
24.1 x ● Circuit breaker Check function no. of switching cycles:
24.2 x ● Self-test check Check function
24.3 x ● base box:
top box:
emergency stop switch Check function gearbox:
deck crane:
converter:
24.4 x ● Test for overspeed with frequency Test gearbox, rotor and brake as well as "rpm ok" gearbox:
generator (only Bachmann) (PitchRunAway) for overspeed by means of a frequency
rotor:
generator. Test results for gearbox and rotor have to be
documented! During test run pay attention to unusual noises (e.g. unusual noises (please yes:
high pitch sound / TI 005). specify):
no:
24.5 x ● Tremor switch Check function by pressing the switch
24.6 x ● Check cable twist 1. Turn nacelle to end position of cable twist by means of the control, check for unusual noises
2. move further by means of the manual yaw adjustment until actuation of the cam switch cable twist. Visually inspect
cable
loop.
3. reset, move back to 0° position, visually inspect cable loop once more
4. Repeat steps for other direction of rotation.

24.7 x ● pushbutton medium voltage breaker OFF Check function

24.8 x ● arc monitoring Check function, with flashgun
26. Nacelle enclosure and stationary ladders
26.1 x All (10) M30-8.8 MoS 2 1350Nm 46 S
Nacelle enclosure on ESM base
● Visually inspect and check the tightness of all screws in the joint
26.2 x All (40) M16-8.8 Dry 200Nm 24 S
ESM base to main frame
● Visually inspect and check the tightness of all screws in the joint
26.3 x All M16-8.8 Dry 200Nm 24 S
Nacelle element fitting
● Visually inspect and check the tightness of all screws in the joint
27. Main carrier
27.1 x All (2x18) M42-10.9 dry 966kN with hydr. tensioning 65 S
Main frame - generator carrier cyl.
● visual and tightness inspections of screw connections

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
28 General checks
Lightning protection
28.1 x ● Visually inspect all parts of the lightning protection for damages
● - check brush wear after disassembly of the brushes, change at hub 1: hub 2:
check of lightning protection system residual height ≤ 7mm before the mark
- check of contact surface yaw 1: yaw 2:
- check rolling ground device for firm seating

28.2 x ● Roller earthing devices / lightning Check function, wear of the race and roller, replace roller if outer diameter < 280 mm actual diameter:
protection ring
28.3 ● Yaw visual check
29. chain hoist
29.1 x ● 1st maintenance and annual check may only be carried out by trained staff
Keep record of date and result of maintenance in the test log book.
30. Deck crane
30.1 x ● 1st maintenance and annual check may only be carried out by trained staff and has to be documented in the manufacturer's log (cf. app.).
30.2 x All (40) M20-10.9 Dry 505Nm 17 I
Deck crane base
● Visually inspect and check the tightness of all screws in the joint
31. Nacelle cooler
31.1 x ● nacelle cooler general inspect cabinet incl. operating doors for damages and corrosion, check condensate drain, remove dirt
31.2 ● suspension nacelle cooler visually inspect and check the tightness of all screws in the joint
check elastomer bearing for damages
32. Dehumidifier nacelle
32.1 ● dehumidifer general check for soiling, clean if necessary, check for damages and overheating, check electrical connections for firm
seating, check bearings for damages and wear.
33. Dehumidifier tower
33.1 ● dehumidifer general check for soiling, clean if necessary, check for damages and overheating, check electrical connections for firm
seating, check bearings for damages and wear.
34. fire protection system
34.1 x Maintenance log Complete manufacturer's maintenance log (for semi-annual maintenance, cf. app.) and return to manufacturer.
34.2 ● annual maintenance has to be carried out by supplier
35. elevator
35.1 ● Maintenance log inspection by trained staff has to be documented in the inspection and servicing logbook (cf. app.). Servicing logbook has
to be returned to the supplier!

36. Heli hoist

36.1 ● heli hoist general visual check for corrosion damages
36.2 x ● threaded joints Visually inspect and check the tightness of all screw joints
36.3 x ● Access Visually inspect and check the tightness of all screw joints, check safety aspects

T-5.1-GP.WA.02-C-EN (B)_annual maintenance

 REpower Systems SE.
Maintenance Specification 5M Platform Date 2012 02 14
X.XB = only 120001 "Brunsbüttel;

Maintenance activity
Hugo"

Notes/description/setpoints Maintenance assessment

Screws

Problem rectified
1st inspection

Inspector
Number of Lubrication Tightening torque Across flats Test point checked

Test point

Date
Screw/nut
Hex. = S, Socket = I

checked
( ) total MoS 2 (µ=0.08) [Nm]/preload [kN] with problems

without
(please describe)
Lubricant
● years
Medium Quantity Notes
1.
37. General checks
Medium Voltage Switchgear Schneider, type WS (36 kV), GMY (24 kV), GHA
37.1 x ● visual inspection, check functionality of every switching device
medium voltage switch-gear, general Attention: Maintenance may only be performed by trained staff!
37.2 x ● SF6-pressure Check of SF6-pressure setpoints according to actual value:
type label:
37.3 x ● HV-voltage detection Check of capacitive voltage detection
37.4 ● medium voltage cable: Visually inspect and check the tightness
connection +MSS check strain relief of all cables Attention: cable must be voltage-free!
38. rescue equipment (requirements for Germany, please follow country-specific requirements!)
38.9 ● stretcher annual check by an expert
38.11 ● height rescue equipment annual check by an expert
if sealed pack: annual visual control for intactness
38.13 ● Offshore Survival kits Box B-D: check for intact sealing or, if open, for completeness of content according to attached list. Reseal box.
39. stationary ladders
39.1 4 intermediate platform (staircase) check by trained staff
39.2 4 yaw area access self-lubrication system yaw check by trained staff
39.3 4 access nacelle check by trained staff
39.4 4 access heli hoist check by trained staff
39.5 4

4x access yaw motor / yaw gearbox check by trained staff

nacelle
39.6 4 generator check by trained staff
39.7 4 staircase over rotor shaft check by trained staff
39.8 4 access oil cooler gearbox check by trained staff
39.9 4 working platform nacelle cooler (if fitted) check by trained staff
39.10 4
3x access rotor hub check by trained staff

39.11 4
rotor hub 3x access hollow shaft / hub boxes check by trained staff

39.12 4
3x access blade bearing check by trained staff

T-5.1-GP.WA.02-C-EN (B)_annual maintenance