TORQUE LIST

S88-2.1 MW

Suzlon Windkraft GmbH

Doberaner Str. 115
18057 Rostock | Germany

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TORQUE LIST, S88-2.1 MW

Table of Contents

1 Scope ............................................................................................... 2

2 General ............................................................................................ 3
2.1 Lubrication of HV bolts ................................................................................................ 4

3 Torques for main connections .......................................................... 5

4 Torques for nut-bolt connections ..................................................... 7

5 Torques for power section connections at bottom cabinet ............... 8

5.1 Torque (Bolts):........................................................................................................... 8
5.2 Torque (Terminals): .................................................................................................... 8
5.3 Torque (Cu-bus bar): .................................................................................................. 8

6 Torques for generator terminal box connections ............................. 9

7 Torques for gear box oil cooling system........................................... 9

7.1 Torques for oil cooling bracket steel screws.................................................................... 9
7.2 Torques for fan housing steel screws ............................................................................. 9

8 How to torque ................................................................................ 10

8.1 Torquing during installation and retorquing ...................................................................10
8.2 Checking torques .......................................................................................................10
8.2.1 Visual check ..............................................................................................................10
8.2.2 Sampling check .........................................................................................................10

1 Scope

This document includes the valid torques for bolt and screw connections to be used for
installation, service and maintenance. In case of bolt / stud replacement during service the
list is applicable for pre-assembled connections also.
This document is valid for S88-2.1 MW in the following variants:
V1/V2 blades
LTV/STV
References:
● IMO: Gear Rim-140106
● IMO: EW Blade 010905
● AE Rotor: D0005704 Service manual AE42V1 - AE42V2 Rotor blades-new

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TORQUE LIST, S88-2.1 MW

2 General
This document includes the valid torques for connections specified in chapter 2.
If you cannot find the connection in chapter 3 use the list in chapter 4.
All electrical related connections are found in chapter 5 and 6.
Due to the fact that the foundation is designed project specific from various designers no
torques for anchor bolts are given in this document. Torques and treatment for anchor bolts
and grouting procedures for shim levelled and from SWK Germany approved foundations can
be found in the document "Procedure for levelling with shims".

Please note: All connections must be torqued with appropriately tested certified and
NOTICE calibrated torquing tools. The torquing tool must have a 5% precision. If using a
hydraulic unit the manometer must be calibrated.

There are three types of bolts used for connections.

1. 2. 3.

Fig.1: Bolt with nut and washer Fig.2: Bolt with washer Fig.3: Threaded stud with nut
and washer

The given torque values are valid only for bolts and nuts greased according to table 1.1.

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TORQUE LIST, S88-2.1 MW

2.1 Lubrication of HV bolts

It is very important that all of the bolt connections must have been prepared according to
greasing instruction (see table 1.1) prior to tightening. In general do not grease studs that
are screwed into a cast-iron blind hole as well as bolt threads with pre-lubricated nut and
washers.

Type of bolt [HV] Lubrication

Description Bolt end Nut Washer Bolt Threaded

thread blind hole
1)
1. Bolt with nut and washer Nut side Pre-lubricated No -
2. Bolt with washer Thread side - MoS2 MoS2 No
3. Stud with nut and Thread side - - No No 2)

washer
Nut side 1) 3)
Pre-lubricated No -
Table 1.1: Greasing instruction

1) For sets of nuts and bolts according to DIN 6914-6916 (HV-sets) the nuts are pre-
greased by the manufacturer so no additional greasing with molybdenum sulphide
(MoS2), trade name is Molycote S2, is required.
2) The internal thread should not have been greased at all. Remove existing lubrication
from internal thread and stud.
3) Additional lubricating causes exclusion of liability.

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TORQUE LIST, S88-2.1 MW

3 Torques for main connections

Connection Width Torque [Nm]

across
Size flats, Grade
from to SW In1)
Standard
[mm] case

Lower mid
Base section M424) 70 10.9 HV - 4500
section
Lower mid Upper mid
M364) 60 10.9 HV - 2800
section section
Upper mid
Top section M364) 60 10.9 HV - 2800
section
640
3) 7) 1280
Tower top flange Gear rim M36 60 10.9 HV 2600
1920
25507)

Yaw bearing Main frame M363) 60 10.9 HV 2600 2800

Adjusting bolt at Bolt 46 1005)

radial pads at
M36 8.8
distance plate Nut 55 400
(yaw system)

Yaw drive Main frame M184) 27 8.8 - 220

Main bearing Main frame M393) 65 10.9 HV 3350 3500

Girder Main frame M363) 60 10.9 HV 2600 2800

Gear box
Main frame M363) 60 10.9 HV 2600 2800
bearing
Gear mount end Gear mount
M202) 6) 30 8.8 - 350
plate pin

Gear box Brake M363) 60 10.9 HV 2600 2800

2)
Hub Rotor shaft M36 [U] 60 10.9 HV-U - 2800
640
2) 7) 1280
Pitch bearing Hub M36 [U] 60 10.9 HV-U -
1920
25507
(300)8)
8)
Blade Pitch bearing M36 60 10.9 HV - 380
+120°

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TORQUE LIST, S88-2.1 MW

1) These values are valid only in case of the stud starting to turn while giving the nominal
torque to the nut.
2) Bolt with washer
3) Threaded stud bolt with nut and washer
4) Bolt with nut and washer
5) Use SHC460 grease on thread. After setting the radial gap between radial polyamide
pad and gear rim, torque the bolt with 100 Nm. To keep the bolt in position, torque the
nut with 400 Nm.
6) Use Loctite 242
7) Special starlike torquing procedure (prepared by IMO) which must be followed.
8) Use Molycote D321 R. Special starlike torquing procedure (prepared by AE Rotor) which
must be followed

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TORQUE LIST, S88-2.1 MW

4 Torques for nut-bolt connections

Size Width across flats Standard Grade Torque [Nm]

SW [metric mm]

M10 16 ISO 4014 / 4017 8.8 41

16 ISO 4014 / 4017 10.9 60
M12 18 ISO 4014 / 4017 8.8 71
18 ISO 4014 / 4017 10.9 104
22 DIN 6914-6916 10.9 HV 100
M16 24 ISO 4014 8.8 170
24 ISO 4014 10.9 265
27 DIN 6914-6916 10.9 HV 250
M18 27 ISO 4014 8.8 220
27 ISO 4014 10.9 370
M20 30 ISO 4014 8.8 350
30 ISO 4014 10.9 490
32 DIN 6914-6916 10.9 HV 450
M24 36 ISO 4014 8.8 600
36 ISO 4014 10.9 850
41 DIN 6914-6916 10.9 HV 800
M27 41 ISO 4014 8.8 880
41 ISO 4014 10.9 1250
46 DIN 6914-6916 10.9 HV 1250
M30 46 ISO 4014 8.8 1190
46 ISO 4014 10.9 1700
50 DIN 6914-6916 10.9 HV 1650
M36 55 ISO 4014 8.8 2100
55 ISO 4014 10.9 3000
60 DIN 6914-6916 10.9 HV 2800
M39 60 ISO 4014 8.8 2800
60 ISO 4014 10.9 4000
65 DIN 6914-6916 10.9 HV 3500
M42 65 ISO 4014 8.8 3500
65 ISO 4014 10.9 5000
70 DIN 6914-6916 10.9 HV 4500
These values are independently from length. They are also valid for threads without a nut if
not otherwise stated in chapter 1 - 2 and 4 - 7.

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TORQUE LIST, S88-2.1 MW

5 Torques for power section connections at bottom

cabinet

5.1 Torque (Bolts):

Size Grade Torque [Nm]

M6 4.6 12
M8 4.6 20
M10 4.6 35
M12 8.8 58

5.2 Torque (Terminals):

Size [sqmm] Size Grade Torque [Nm]

1.5 – 2.5 M2.5 4.6 0.8

2.5 – 4.0 M3 4.6 1.0
6.0 – 10. 0 M4 4.6 2.0
16.0 M5 4.6 4.0
35.0 M6 4.6 5.0

Torque for compensation capacitor

Clamp combi screw M5 max. 2.0 Nm
Stud at the bottom of cylindrical aluminium casing M12 max. 10.0 Nm

5.3 Torque (Cu-bus bar):

Size Grade Torque [Nm]

M4 4.6 2.0
M5 4.6 3.2
M6 8.8 6.0
M8 8.8 15
M10 8.8 30
M12 8.8 60
M16 8.8 120

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TORQUE LIST, S88-2.1 MW

6 Torques for generator terminal box connections

Note: S88-2.1 MW Elin generator only

Cables fixing Bolt Size Width across Standard Grade Torque

flats [Nm]
from to SW [metric mm]

winding stator M12 18 ISO 4017 8.8 71

winding rotor M12 18 ISO 4017 8.8 71

outgoing stator M16 24 ISO 4017 8.8 170

outgoing rotor M16 24 ISO 4017 8.8 170

7 Torques for gear box oil cooling system

7.1 Torques for oil cooling bracket steel screws

Note: S88-2.1 MW Hydac cooling only

Size Torque [Nm] ±10%

M8 20
M10 40
M12 60
M16 150
M20 303
M24 290

7.2 Torques for fan housing steel screws

Note: S88-2.1 MW Hydac cooling only

Size Torque [Nm] Precision [%]

M8 25 ±5
M10 45 ±5
M12 80 ± 10

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TORQUE LIST, S88-2.1 MW

8 How to torque
In general all bolt connections that are fastened to the final torque have to be marked. This
mark needs to reach onto the surface of the connected part to make it visible in case the bolt
has been turning.
Retorquing and checking torques is done by continuing the tightening only.

8.1 Torquing during installation and retorquing

Torquing tool Quantity Torque [%]

Manual 100% 100%

Electric or hydraulic 100% 100%

8.2 Checking torques

Checking torque includes two steps; visual surface inspection and mechanical sampling
inspection.

8.2.1 Visual check

Check visually if any bolt is damaged or missing. Check that all bolt markings are still
connecting joint parts.
In case of deviations replace bolt/stud including washers.

8.2.2 Sampling check

Always check connections with the same kind of tool used for torquing and retorquing.

1)
Torquing tool Quantity Torque [%]

Manual 10% 110%

Electric or hydraulic or other 10% 100%
1) Connections check according to DIN 18 800 part 7.

In case of deviations:
− In case of finding a bolt or stud that turns further during check, retorque all bolts.
− Bolts or nuts that can be turned more than 60 degrees are to be replaced including
washers.

Mark again all bolts that have been turned less than 60 degrees during check. If possible use
another colour or take a picture. Add date to the marking.

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 lnstallationand Maintenance
lnstructionsfor IMOGearRims

Usedfor Yawadjustmentwith the followingWindTurbines:

Suzlon 350 kW
62- 12 M2A|2-O4607

Suzlon 600 kW
62- 14 1764t247650
62- 14'1764t2-57650

Suzlon1.25MW
62-162096/2-04888
62-162096/2-54888
62-t6 2096/2-07666
62-162096/2-57666

Suzlon1.5MW
61-202840/4-07690
61-20 2840t4-57690

Suzlon 2 MW
61-20 3020t2-05784
61-20 302012-55784

Copyrightby IMO MomentenlagerGmbH,October2004;Gremsdorf/ Germany

All rightsreserved

lssued:April'l1'r 2005 PageI

Rev.:'l (lssued:September
01st,2005)
 rM0
lnstallation instructionsfor GearRims
and maintenance
Preface

The followinginstructionsprovideSuzlonwith all the informationrequiredto be able

lo correctlyinstalland maintainIMOGearRims.
are providedwith a revision.lnstallationand maintenanc€
All instructions inslructions
with oreviousrevisionsare invalid.
Pleasemakesurethat you are alwaysworkingwith the latestrevision!

Theseinstructions shouldbe attachedto yourproductor the end productor included

and maintenanceinstructions.
in its installation
All the workstepsgivenmustbe carriedout by suitablyqualifledpersonnel.

IMOdoes not acceptliabilityif:

1. The installation
and maintenanceinstructionsare not followed
2. The contentsare not passedon or are incorrectlypassedon to third
Darties.

Notes

In the followingtext specialadviceand sequencesare specifiedwhichmustbe

followed.
You can find detailsof the technicalpropertiesof the GearRimfromthe technical
orooosat.

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01st,2005)
 rMo
Tableof contents
0. Transport,handlingand3toragespecifications
0.1Transport,
handling
andstorage
l. lnstallation
1.1 PreDarations
for installation
1.'1.1 Cleaningof the GearRimandthe mountingstructure
1.1.2 Determination of permissible
deviations
anddeformations
in the mountingstructure
1.1.3 Lubricätion
of the GearRim
1.1.4 Setectionof mountingbolts
1.1.5 Selectionof tighteningtorques
'1.2Installation
of GearRim
1.2.1 PositioningofGear Rim
't.2.2 Attachment ofthe cear Rimwithbotts
1.2.3 Adjustingthe circumferentjal
backlash
1.2.4 Functiontest

2. Maintenance/ safety inspection and lubdcation

2.1 Checkingof the mountingbolts

2.2 Relubricationof the teeth
2.3 Relubricationintervalsfor the teeth
2.4 Lubricants
2.5 Dismantlingthe GearRim
2.6 Assignments

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 tM{:3
0. Transport.handlinqand storaqe specitications

0.1 Transport,handling and storage

Transportonly in the horizontalposilion.Avoidjolts.

The GearRimsmustonlybe handledwith workgloves.

GearRimsare normallyprovidedwiththreadedholesintowhichliftingeye boltscan
be screwed.This permitssafehandlingby meansof liftinggear.Forlhis pleasetake
noteof lhe relevantstatutoryregulations.
cear Rimsmustbe liftedby the hoistwith
the weightdistributeduniformlyovereachof the transportholesaroundthe
penphery.

Storagein the horizontalposition.lf severalsimilarcear Rimsare to be stackedon

top ot one anothertheremustalwaysbe an intermediate layerof woodbetween
themand storageshouldonlybe in closedrooms.

The preservation
agentusedis effectiveagainstcorrosionfor about3 monthsas long
as closedpackaging
is used.A longerstorageperiodwouldrequirespecialmeansof
preservaüon.

1. Installation

1.1 Preparationsfor installation

1.1.1Cleaningof the GearRim and the mountingstructure

1. Removeextraneousmaterialsfrom the supportingsurfaces(includingresidual

paint,weldingbeads,burrformation)
2. Removecorrosionprotectionmaterialsfrom the supportingsurfacesof the
GearRim.

In doingthismakesurethat:
- No cleaningagentpenetratesthe GearRim
- The relevantregulationsare followed(e.9.manufacturer's
instructions,
safety
at workand environmental regulationsetc.)
- No cleaningagentsare usedwhichattackthe sealingmaterials.

Commonly-used
cleaningagents:Coldsolvents(e.9.petroleumether,dieseloil,
KaltrylKEV)

The supportingsurfacesmustnot be paintedor spreadwith any form of media.

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01st,2005)
 f rvlO
1.1.2Determiningpermissibleflatnessdeviationöpand perp€ndicularity
deviationöw,andthe permissibledeformation6v of the mountingsurfaceof
the supportingstructure
Table1: Permissible p erpendicularity
flatnessincluding deviations
forGearRims

Windtuöines Suzton350kW Suzlon600kw Suzlon1.25tt|w Suzlonl.5MWSuzton2MW

Flatnessincl.peDendicularity
devialionpersupponing 040 0.50 0.60 0.70 o.ao

Table2: Permissible
deviationof mountingstructure,undermax.load,for GearRims
\Mndturbines Suzton350kW Suzton600kW Suzton1.25MW Suzton1.5[4W Suzton2 MW
Flahessincl.perpendicularity
devialjonpersupponing 1.0 1.U 1.60 1.86 212

Permissibleperpendicularity
deviationöw(tilting)is basedon the actualflangewidth
and may onlyamountto one halfof the values in tables.l and 2.

The maximumresidualvaluefor the flatnessdeviationöp(waviness)alongthe

circumferential
maytotalto only 1 time per 180deg.Theform,mustresemblea sine
curvethat graduallyrisesand falls.

The indicatedvaluesreferto the gearing.In caseit is requiredto reducethe values

furtherbecauseof the slidebearingfunction,thesedecreasedvalueshaveto be
followed.
tlekh: Pernrisible
.uBeol flatness
devatonol themountin!
nruciure
andltalness
and
perpend(uaily devGlioN
onthemountrno nru(turc

<_ pem,sb e curye&

,<r::-ts
Perpend
o ai'ryddElon öw
/-

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01st,2005)
 FM{}

1.1.3Lubricationof the GearRim

GearRimsare greasedwith the specifiedlubricanl274 Moly Ep Synthetic Blend

Greaseand may only be relubricated
withthis grease.lf othergreasesare to be
usedthey mustbe approvedby IMO beforeuse.
The GearRim mustbe relubricated
beforestartingup.

'1.1.4Selectionof mounting
bolts
The followingmountingboltsare to be usedfor fixingthe bladebearing.
Windturbines Suzlon350 kW Suzlon600 kW Suzton1.2SMW
Boltsconforming
with DlN6912 DtN6912 OtN6912
Boltsize M24 M27 M30
Boltquaiity 10.9 10.9 10.9
Washers DIN6916 DtN6916 DtN69i6

Windturbines Suzlon1.5Lilw Suzton2 MW

Boltsconfomingwith DIN6912 DtN6912

Boltsize l\436 M36
Boltquality 10.9 10.9
Washers DIN6916 DIN6916

Pleasenote:

. The grippinglengthratio(grippinglengthto boltdiameter)is to be keptto a

minimumof >5 to max.<10.
. Boltswithfull threadsare not permissible
. Functionand servicelifeof the GearRim,as well as the durabilitvof the bolted
connection.will be influencedby non-compliance.
. lf the permissibleinterfacialpressureis exceededwashersofthe
corresponding size and strengthmustbe inserted.
. In generalnew bolts,nutsand washersshouldbe used- alsowhenthe Gear
Rimis exchanged.

Table3: Permissibleinterfacialpressurefor differentmaterials

Material Max.interfacialpressurein N/mmz

St50/ C45 N / 46Cr2N 420
46Ct4Vl4zCtMo4V 7O0

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0lst,2005)
 rM{}

1.1.5Selectionof tightening torques

In the normalsituation the mountingboltsare sufficienflysecuredby applyingthe

correctinitialtension.

. Additionalsecurityfor the boltedconnectionmay howeverbe requiredin the

caseof shockloadsor vibrationswith Loctiteor Nord_Lock
screwlockino
wasners.
. The useof splivspringwashersis not permissible.
. lf washersare usedthey shouldbe of suitablestrength
'1.2Installationof the Gear
Rim
1.2.1Positioningthe cear Rim

1.Onlylift GearRimwith suitablehoists

2. Putthe GearRim in correctpositionon the assemblyrig.

3.Thebacklash(seepoint1.2.3)hasto be observed.

1.2.2Attachmentof the Gear Rim with bolts

The GearRim mustbe attachedin the unloadedstate.

The followingproceduremusl be followedto avoidnon-permissible

deviations
betweenthe boltgrippingforces.

1. Spraythe boltthreadswith MoS2to ensurea uniformfrictionalresistance.

2. Checkthat all boltscan easilybe screwedintothe threads.
3. Fit all the boltswith washersand tightenwith a torqueof aboutSONm
4. Pretightenboltswith washerscrosswisein 4 steps.

Tighteningtorquesfor the differentturbinesand tighteningsteps:

Suzlon350kW Suzton600kW Suzlon1.2SMW

M24 M27 M30
Step1 180Nm 250 Nm 375 Nm
Step2 360Nm 500Nm 7S0Nm
Slep3 540 Nm 750 Nm 1125Nm
Step4 725 Nm 1070Nm 1450Nm
Suzlon1.5kW Suzlon2 MW
M36 M36
Step 1 640 Nm 640 Nm
Step2 1280Nm 1280Nm
Step3 1920Nm 1920Nm
Step4 2550Nm 2550Nm
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Rev.:1 (lssued:September
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 Itvt0

5 . Aftereachsteprolatethe innerringthroughonefullturn.
6 . Aftertightening
thebolts,position
thegearrimso thatthegreenmarkson the
teetharein theareaof thedriveDinion.

L2.3. Adjusting the circumferentialbacklash

a-

Duringassemblythe circumferential backlashbetweenthe gearand GearRim must

be set.The closestpointof the teethis markedin greenforlhis purpose.The gear
rim shouldbe rotatedso that the greenmarkingon the teethis locatedin the alea of
the drivepinion.The set valuefor circumferential
backlashis:

ör= 0.03to 0.04. Modulem

The circumferential
backlashshoutdbe establishedfor checkingpurposeswith a
feelergaugeor a soft copperwire.lf deviationsare foundoverthe presDecified
valueslhe axlecentredistanceshouldbe mrrectedby rotatingthe cam on the
slewinggear.lf morethan one drivepinionis used,all stepsfor eachdriveDinionhas
to be done.Afterelectricalinstallation
the cear Rim shouldbe completelvrotated
whilecheckingthat no tightpositionsexist.Forthis purposethe currentconsumption
of the drivemotormustbe measuredand recorded.

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 $sdü

The followingvaluesfor circumferential

backlashon the bladebearingsare required.
Windturbine Suzlon
350kW Suzton
600kW Suzlon
1.25MW
Modulem 12 16 i6
Circumferential
backlash 0.36to 0.48mm 0.48to 0.64mm 0.48to 0.64

Windturbine Suzton1.5lvlw Suzlon2lllw

lvlodulem 20 20
Chcumferential
backlash 0.60to 0.80 0.60to O.BO
mm

'1.2.4Function testing

The GearRim mustturn smoothlywith properiytightenedmountingboltsand

correctlyconnecteddrive.Deviationsin the mountingstructureas well as the
influenceof externalloadscan stronglyinfluencethe frictiontorque.

1. Rotatethe mountedGearRim severaltimes.

2. Checkthat the GearRim runssmoothlyand withoutjolts.

Afterthe functiontestthe tighteningtorquesof the mountingboltsshouldbe checked

agarn.

2. Itaintenance / safetv inspectionsand lubrication

2.1 Checkingof the mountingbolts

In orderto compensatefor settlingit is necessaryto retightenthe boltswith the

specifiedtighteningtorque.Thisshouldbe donewithoutany additionaleKernal
stresseson the boltedconnectionand at the latestafter3 months.
This checkshouldbe repeatedat leastonceeachyearwithinthe scopeof the
normalmaintenance work.
lf boltshavecomeloose(alsonutsand washers)then all bolts- as well as anv nurs
and washers- shouldbe replacedby new ones.

2.2 Relubricationof thc teeth

In orderto avoidwear in the teethand excessiveheatingand noise,the teethmust

alwaysbe suppliedwith a suitablequantityof lubricant.The lubricantshouldbe fed
as closeas possibleto the mntactareabetweenthe pinionand the GearRim.
Permanentdamagecan be causedto the teethif the gearsrun dry.

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01st,2005)
 rMo
2.3 Relubricationintsrvals ior the toeth
Theamountof greaseus€dcanvarygreaflyaccordingto the typeof lubricantand
the deliverymethod.We havehadgoodexperiencewithadheiivelubricants.lt is
important hereto ensurethatanappropriate
filmof lubricant
is alwayspresent.

,Lubricationpinions'withcentrallubricationor electricgreaseboxeshaveprovedto
be particularlyefiective.
2.4Lubricanta
2.4.1Lubricants
fortheteeül

Table9

Productname Operatingtemperature
AralubLFZ1
qltigrade
-30"to +130"
-20'to +120
! l
WRT
Texaco Crater2X Fluid -20' to +120'
CARDREXA DCl -30' to +130'
Suret Fluid4k -25' to +130'
Klüber GraflosconCA 901 -20' to +140'
-40"to +120"
-20"to +'120"
CardiumComDound C -30"to + 70'
274 MolyEP Synthetic -37" to +175'
BlendGrease

2.5 Dbmenüingt|reGearRim
lf a GearRimhasto be exchanged, theprocedure
forthisis thesameasfor
installationbut in the reverseorder.
GearRimsmustbe dispos€d of according
to themabrialsof the individual
components. Theyare nottakenbackby the maker.\Men theyaredisposedof the
relevantenvironmental
regulalionsmustbe stricflyfollowed.

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 rMo
2.6Assignments

Thefollowing
assignments
arevalidfor thisdocument:
SuzlonGearRims& GearRims

s33 (350kWWTG)
GearRim, C60 (4+ monthleadtime) 62-121428/2-04607
GearRim,42CrMo4V 62-12 1428/2-04607

s52(600kw wTG)
GearRim 62-14t7 64/2-07
650
62-141764t2-5'7650

s64, 566, 566 DD (1.25MW WTG)

GearRim 62-162096t2-04888
62-162096t2-54888

s70 (1.25MW vwc)

GearRim 62-162096t2-0't
666
62-162096/2-57
666

s78/82(t.s nW WTG)
GearRim 6t-20 2840t4-07
690
6t-20 2840/4-57
690

s88 {2 MWWTG)
GearRirn 6t-203020/2-05'184
6t -203020/2-ss784

The latestrespectivedrawingrevisionwill be valid.

01*,2005

lssued:ADril11'" 2005 PageI I

Rev.:1 (lssued:September
01st,2005)
REFERENCE COPY
 Revision history

Revision Date Page(s) Description

00 28-07-2005 All Original for AE42V1
01 27-10-2006 All Version for AE42V2
02 29-01-2007 All Now valid for three blade types
8/9 Method for pre-torque checking changed
03 23-2-2007 All Now valid for only AE42V1 and AE42V2 blades
04 20-03-2007 9 Torque value corrected

The differences of the underlying revision of this report with the previous version is indicated as follows:

New or changed data or sentences are written Italic and underlined.

Deleted items have been given a double strikethrough.

Contents
1 INTRODUCTION ....................................................................................................................................... 3

2 SCOPE OF SUPPLY ................................................................................................................................. 4

3 TRANSPORTATION OF THE BLADES BY LORRY .................................................................................. 5

4 HOISTING INSTRUCTIONS ...................................................................................................................... 6

5 ASSEMBLY................................................................................................................................................ 7
5.1 Materials / tools required for assembly................................................................................................ 7
5.2 Handling, hoisting ............................................................................................................................... 7
5.3 Check-points before assembly............................................................................................................ 7
5.4 Blade fixation ...................................................................................................................................... 8
5.5 Finishing ............................................................................................................................................. 8

6 MAINTENANCE AND INSPECTION SCHEME.......................................................................................... 9

6.1 Studs pretension ................................................................................................................................. 9
6.2 Corrosion ............................................................................................................................................ 9
6.3 Lightning protection............................................................................................................................. 9
6.4 Surface condition .............................................................................................................................. 10
6.5 Dirt .................................................................................................................................................... 10
6.6 Vent holes......................................................................................................................................... 10

All rights reserved. Disclosure to third parties of this document or any part thereof, or the use of any information contained therein for purposes other than
provided for by this document, is not permitted, except with the prior and express written permission of AE Rotor Techniek B.V.

D0005704 Service manual AE42 Rotor blades Page 2/10

1 INTRODUCTION

This service manual is a guide to the installation and maintenance activities to be performed on the AE42
rotor blades. This manual deals with the following topics:

x Transport
x Lifting and assembly
x Maintenance and inspection scheme.

The rotor blades are of an aerodynamically shaped monocoque design, with a light skin structure. This
lightweight skin requires extra attention during hoisting, transportation and assembly of the rotor blade.

The blades are equipped with a circular stiffener of full laminate at the root side which also acts as a
service platform. This stiffener has a manhole closed by a cover of sandwich. The cover is attached with
“big head bolts”. The platform is strong enough to carry the weight of one person.

Caution is also required for the pre-assembled studs at the blade root. They must not get damaged, as
these studs fix the blade to the hub by means of a high pre-stress.

The noise-optimised tip is to be protected against damage, as damage to the tip (even slightly) may cause
additional noise during operation (whistling).

The blades are of low maintenance design. For optimum reliability and performance however, the
inspection scheme presented in this document has to be followed.

It is desirable to record the installation, inspection and maintenance activities in the wind turbine logbook.

Note: AE-Rotor Techniek is not liable for any direct or indirect damage, resulting from the use of
information contained in this document.

All rights reserved. Disclosure to third parties of this document or any part thereof, or the use of any information contained therein for purposes other than
provided for by this document, is not permitted, except with the prior and express written permission of AE Rotor Techniek B.V.

D0005704 Service manual AE42 Rotor blades Page 3/10

2 SCOPE OF SUPPLY

The supply of one set of rotor blades comprises:

x Three rotor blades, with the following markings/identifications:

-Identification plate at the blade root exterior showing:
- Blade type
- Blade number
- Year of construction

- A plate marking the zero position (tip plane reference) at the blade interior

- Two markers indicating a hoisting symbol, placed at the centre of gravity in

longitudinal direction near the trailing edge of the blade. At this position the
blade can be hoisted with a (nylon) hoisting sling with a minimum width of 200
mm. If this kind of sling is not available a nose and tail protection cap has to be used.

x Fasteners for mounting the blades to the hub (Quantity per blade):
- 60 nuts, M36 class 10, DIN 6915;
- 60 washers for M36, DIN6916;

x A support for the root end of the blade

x A support for the tip side of the blade at the nose side

x A profiled cap for protecting the vulnerable tail side when the blade is strapped up on the lorry.

x A profiled cap for protection of the nose during lifting activities.

All rights reserved. Disclosure to third parties of this document or any part thereof, or the use of any information contained therein for purposes other than
provided for by this document, is not permitted, except with the prior and express written permission of AE Rotor Techniek B.V.

D0005704 Service manual AE42 Rotor blades Page 4/10

3 TRANSPORTATION OF THE BLADES BY LORRY

The positioning of the blades on the lorries has to be such that a safe and damage free transport is possible.
If needed a protection frame should be used.
A possible positioning is as follows:
x The lorry loaded with two blades has one blade directed with the tip backwards, and the other blade
directed with the tip forwards;
x The lorry loaded with one blade has the blade directed with the tip backwards.

Each blade is supported on the loading floor of the lorry at two points: At the root side by means of a sufficient
strong support which carries the cylindrical end of the blade. Attachment to the studs only to prevent of tilting.
Between 0,6 L and 0,7 L towards the blade tip by means of a support on the nose,
Per blade nylon slings are used for lashing the blade to the lorry:
x 1: around the cylindrical part of the blade root;
x 2: at the leading edge support; in this case use the protection over the trailing edge of the
blade.

The mass of one rotor blade is approx. 7000 kg including studs.

Remarks:
1. Arrange the blades in such a way that there is sufficient relative inter-space between the blade and the
loading floor of the truck, particularly at the tip side (sagging of the blade).
2. Check the tension of the lashing slings regularly during transportation.
3. Due to exceeding the maximum allowed width of 2.5 m for regular transport, special transport might be
necessary

Detailed description of the requirements are to be found in instruction: W00012XX “ Handling and Transport”

All rights reserved. Disclosure to third parties of this document or any part thereof, or the use of any information contained therein for purposes other than
provided for by this document, is not permitted, except with the prior and express written permission of AE Rotor Techniek B.V.

D0005704 Service manual AE42 Rotor blades Page 5/10

4 LIFTING INSTRUCTIONS
There are two methods for lifting the blades. The first method is the easiest way for loading / unloading the
blades on the truck. The second method is the method for mounting the blades at hub height.

Method 1:

The blades can be hoisted by means of a single nylon sling, which must have a minimum width of 200 mm, if
this strap is not available protection caps have to be used. The strap should be positioned around the blade in
the center of gravity (hoisting point markers) with the leading edge pointing down.
If required, the blades can be hoisted with the trailing edge pointing down. In this case, it is necessary to
protect the trailing edge by the protective profile provided.

N.B. When the blades are lifted all the way to hub height, this first method is not allowed !

Method 2:

The blade will now lifted at two points on either side of the gravity centre. This can be performed either by two
cranes or by a single crane using a spreader and two nylon slings around the blade at a distance of at least 5
meters apart. In this case two separate steering lines are required to keep the blade under control from the
ground.

All rights reserved. Disclosure to third parties of this document or any part thereof, or the use of any information contained therein for purposes other than
provided for by this document, is not permitted, except with the prior and express written permission of AE Rotor Techniek B.V.

D0005704 Service manual AE42 Rotor blades Page 6/10

5 ASSEMBLY

5.1 Materials / tools required for assembly

The following tools/material are required to hoist and mount the blades on the hub:

Handling:
x Two nylon slings with a minimum width of 200 mm.
x Optional: Steering lines of sufficient length
x Protective profile: included in first delivery
x Tip and root support for damage free storage of the blade after unloading

Assembly:
x Calibrated torque spanner with a range up to at least 2000 Nm. The socket has a hexagon width of 60 mm
and must be high enough to fit over the studs with the indicator knob.
x Two cans of MOLYKOTE D321 R spray or equivalent Mos2- based spray lubricant for lubricating the
studs before assembly.

5.2 Handling, lifting

Beware of the following points:
x Use the protective profile to protect the vulnerable trailing edge
When the blades are unloaded, and lowered to the ground, it is necessary to support the leading edge of
the blade sufficiently with a specially designed support.
x Take good care of vertical hoisting.

5.3 Check-points before assembly

x Transport damage of the blade surface and-structure
x Transport damage of the blade tip (whistling )
x The vent hole in the tip must be open and clean;
x Studs at the blade root must be undamaged and clean.

All rights reserved. Disclosure to third parties of this document or any part thereof, or the use of any information contained therein for purposes other than
provided for by this document, is not permitted, except with the prior and express written permission of AE Rotor Techniek B.V.

D0005704 Service manual AE42 Rotor blades Page 7/10

5.4 Blade fixation
The blades are fixed to the rotor hub by means of 60 studs and nuts, following the pre-stressing method
described below. Following other procedures is not allowed

The position of the blade, relative to the plane of rotation is determined by the wind turbine manufacturer (also
see supplied interface drawing).
The blade root contact surface is sufficiently protected against moisture attack of the laminate by means of an
epoxy resin finish.
Washers and nuts of correct quality are supplied with the blades.

1. Lubricate the studs, the nuts and the washers with ample MOLYKOTE D 321 R spray, shake the spray
can well before use for at least two minutes.
2. Mount the washers and nuts initially by hand.
3. With a torque spanner, a torque of approximately 300 Nm is applied to all the M36 nuts in an equally
divided sequence.
4. Sequentially, a torque exactly 380 Nm is created with a calibrated torque spanner;
5. Afterwards, the nuts are to be turned further over an angle of 120o one by one.
6. If “Rota”bolts are available: After tightening the indicator knobs must be unable to move. If one or more
are still loose, continue with the procedure described in paragraph 6.1.

5.5 Finishing
After assembly of the blade the lightning spark bridge must be adjusted such that the teeth are facing the
outer ring of the blade bearing at a distance not larger than 1 mm and can run freely between the dust seal
and the washers of the attachment bolts.

All rights reserved. Disclosure to third parties of this document or any part thereof, or the use of any information contained therein for purposes other than
provided for by this document, is not permitted, except with the prior and express written permission of AE Rotor Techniek B.V.

D0005704 Service manual AE42 Rotor blades Page 8/10

6 MAINTENANCE AND INSPECTION SCHEME
Timetable maintenance and inspection scheme.

Item Subject 4-10 weeks Once a year

after assembly
6.1 Studs pretension X X
6.2 Corrosion X
6.3 Lightning protection X
6.4 Surface condition X
6.5 Dirt X
6.6 Vent holes X

6.1 Studs pretension

Check the pretension at the special studs with the tension indicator by trying to turn the knob. If the knobs are
still immobile the tension is sufficient. If one or more knobs are loose, do the following:

1. Give a small extra rotation to the nut on the Rota stud until it is fixed again and mark on the blade
bearing the angle of this extra rotation and rotate the nut of the Rota stud 300 farther.
2. Give the 10 nuts adjacent a “loose” Rota stud (5 at either side) the same total extra rotation as the
central Rota stud. (The nut right in the middle between two loose Rota studs must be given the
highest rotation of both possibilities)

If no “Rota”bolts are present check the tension as follows:

Take 6 random studs distributed about the circumference, release the nut and assemble again with the
original procedure: 380 Nm plus 120 degrees extra rotation. Note the torques, which are required to reach the
final position and take the average of these 6 values (If one of them is clearly a deviation of the average, skip
this value and take the average of the remaining five.). Apply the average torque to all other nuts of the
connection after a small release counter-clock wise. If any anomalies are observed: report the results to
AE-Rotor Techniek.

6.2 Corrosion
The blade root studs, washers and nuts have a sufficient corrosion protection layer. Slight corrosion of these
parts, mainly due to slight mounting damage is not serious. Heavy corrosion should be reported to AE-Rotor
Techniek.

6.3 Lightning protection

Small surface defects on the lightning receptor in the tip can occur. Larger lightning defects (black spots,
especially at receptor circumference with dimensions of more than 1 cm) should be repaired. Burrs have to be
sanded flat, craters to be filled and coating to be restored.
After a lightning strike the lightning cable at the inside of the blade has to be inspected over a length as long
as possible. Special attention should be given to delamination of the covering laminate layer. Also it must be
verified if there has been any lightning entering halfway the length of the cable through the surface of the
blade.

All rights reserved. Disclosure to third parties of this document or any part thereof, or the use of any information contained therein for purposes other than
provided for by this document, is not permitted, except with the prior and express written permission of AE Rotor Techniek B.V.

D0005704 Service manual AE42 Rotor blades Page 9/10

6.4 Surface condition
At each annual check, the blade surface should be checked for the following defects:

1. Slight damage: This type of damage has not direct influence on the technical life or performance of the
blade. Damages that fall in this category are: Scratches, local matt surfaces due to earlier repairs, and
slight chipping at the thin blade tip, resulting in whistling. Only this type of damage may be repaired
without notice to AE-Rotor Techniek. All other damages are to be reported AE-Rotor Techniek.

2. Erosion damage: This damage is only situated at the leading edge of the blade, from the blade tip up to
few meters towards the blade root. Common damage that falls into this category are small pits in the blade
surface, some times larger and completely through the PU coat surface up to the structural laminate
(Coloured green to brown).

3. Cracks: Depending on the climate and the blade loading smaller or larger cracks in the blade surface can
occur. Any larger crack falls under the category 5, major damage.
4. Blisters: Blisters in the blade surface can occur when locally no sufficient bonding between blade coating
(white protective outer surface) and underlying structural laminate is present anymore. This damage
should be repaired; as the cavity under the blister accumulates moisture will expands at temperatures
below freezing point leading to cracks.

5. Major damage: Major damage is classified as damage not resulting from normal handling of the blades
and/or normal operation of the wind turbine. Larger cracks or dents in the structural laminate are the most
common damages. Also, locally bonding defects at the trailing edge are classified as major damage.

Any damage reported should be repaired, even the slightest damage in order to prevent growth to a major
damage category.

Special care must be taken in case of major damages: The turbine should be taken out of production and a
detailed report describing the damage and possibly the wind and weather conditions, along with data on actual
turbine parameters such as maximum rotor speed, pitch angle, power etc, should be submitted to AE-Rotor
Techniek.

6.5 Dirt
Depending on the local conditions (pollution, insects, etc.) sooner or later dirt build-up may take place
especially at the nose of the profile. Excessive dirt (roughness comparable to rough sanding paper, and/or
thickness of a few millimeters) on the nose affects the performance and noise emission of the blades
negatively. In this case cleaning of the blades is necessary using water and a mild detergent.

6.6 Vent holes

At each annual check, it should be checked if the vent hole in the tip is still open. If this is not the case, they
have to be cleaned and opened with a normal spiral drill with a diameter of 5 mm.

All rights reserved. Disclosure to third parties of this document or any part thereof, or the use of any information contained therein for purposes other than
provided for by this document, is not permitted, except with the prior and express written permission of AE Rotor Techniek B.V.

D0005704 Service manual AE42 Rotor blades Page 10/10