Installation of blades

Document no.: 0081-5575 V02

Class: RESTRICTED
Type: T09
Date: 2020-04-21

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VESTAS PROPRIETARY NOTICE: This document contains valuable confidential information of Vestas Wind Systems A/S. It is protected by copyright law as an unpublished work. Vestas reserves all patent, copyright, trade secret, and
other proprietary rights to it. The information in this document may not be used, reproduced, or disclosed except if and to the extent rights are expressly granted by Vestas in writing and subject to applicable conditions. Vestas
disclaims all warranties except as expressly granted by written agreement and is not responsible for unauthorized uses, for which it may pursue legal remedies against responsible parties.
Installation of blades
Document no.: 0081-5575 V02 · Class: RESTRICTED · Type: T09 Page 2 of 58

Wind turbine type

Read the full document before you start to do work.

Send questions or concerns about the document to Vestas Wind Systems A/S.

Wind turbine type Mk version

V117-4.0/4.2 MW Mk 3E

V136-4.0/4.2 MW Mk 3E

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V150-4.0/4.2 MW Mk 3E

2.
Change description

Description of changes
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Updated section 4.2 Reference documents, page 6, section 7.1.1 Vestas multi-blade installer,
page 8, section 7.1.3 Multi-blade T-yoke, page 9, section 7.1.4 General equipment, page 9,
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section 7.3 Tools for tightening of the M30 stud bolts, page 10, section 7.4 Tools for tightening
of the M36 stud bolts, page 11, section 9 Consumables, page 11, section 10 Weights, page 11,
section 12.3.1 To put the nacelle and the hub in the correct position, page 13, section 12.4 To
use the Vestas multi-blade installer, page 19, section 12.8 To guide the blade into the hub,
page 28, section 12.9 To install the washers and the bolts, page 33, section 12.10 To remove
the lifting equipment, page 35, section 12.11 To rotate the hub, page 37, section 12.12 To
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install the LCTU, page 39, section 12.13 To tighten and tension the stud bolts, page 40, section
12.14.2 To use the hydraulic tensioning tool, page 47, section 12.14.3 To prevent the blade or
blade bearing joints from corrosion, page 50, and section 14 To complete the procedure, page
58.
pp

Added section 7.2 Tightening tools, page 9.

Deleted section ‘T-lifting yoke’.
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Installation of blades
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Table of Contents

1 Safety ........................................................................................................................... 5
2 Educational requirements of service technician .................................................... 5
3 Abbreviations and technical terms .......................................................................... 5
4 Referenced documentation....................................................................................... 6
4.1 Safety documents......................................................................................................... 6
4.2 Reference documents .................................................................................................. 6
5 Purpose ....................................................................................................................... 7
6 Note.............................................................................................................................. 7

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7 Tools ............................................................................................................................ 8
7.1 Lifting equipment .......................................................................................................... 8
7.1.1 Vestas multi-blade installer........................................................................................... 8
7.1.2 2-crane lift ..................................................................................................................... 8
7.1.3 Multi-blade T-yoke ........................................................................................................ 9

2.
7.1.4 General equipment ....................................................................................................... 9
7.2 Tightening tools ............................................................................................................ 9
7.3 Tools for tightening of the M30 stud bolts................................................................... 10
7.4 Tools for tightening of the M36 stud bolts....................................................................11
7.5
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Electrical equipment ....................................................................................................11
8 Spare parts .................................................................................................................11
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9 Consumables .............................................................................................................11
10 Weights.......................................................................................................................11
11 Estimated time use................................................................................................... 12
12 Procedure.................................................................................................................. 12
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12.1 Lockout-tagout start.................................................................................................... 12

12.2 To identify the stud bolts at the TC mark .................................................................... 12
12.3 To prepare the hub...................................................................................................... 12
12.3.1 To put the nacelle and the hub in the correct position ................................................ 13
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12.4 To use the Vestas multi-blade installer ....................................................................... 19

12.5 To use the T-lifting yoke.............................................................................................. 24
12.6 To do a 2-crane lift ...................................................................................................... 25
12.7 To lift the blade............................................................................................................ 26
12.8 To guide the blade into the hub .................................................................................. 28
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12.9 To install the washers and the bolts............................................................................ 33

12.10 To remove the lifting equipment ................................................................................. 35
12.11 To rotate the hub......................................................................................................... 37
12.12 To install the LCTU ..................................................................................................... 39
12.13 To tighten and tension the stud bolts .......................................................................... 40
12.13.1 To do a check on the length of the protruding thread ................................................. 41
12.13.2 Sequence to tighten the stud bolts ............................................................................. 43
12.13.3 To tighten the stud bolts with the hydraulic tool.......................................................... 44
12.14 To tension the stud bolts............................................................................................. 46
12.14.1 To adjust the pressure ................................................................................................ 46
12.14.2 To use the hydraulic tensioning tool ........................................................................... 47
12.14.3 To prevent the blade or blade bearing joints from corrosion ...................................... 50
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12.15 To install the grease container for the blade bearings................................................ 51

12.16 To remove the safety wire in the hub.......................................................................... 51
13 To install the covers ................................................................................................. 52
13.1 End of installation ....................................................................................................... 58
13.2 Lockout-tagout end..................................................................................................... 58
14 To complete the procedure...................................................................................... 58

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Installation of blades
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1 Safety 0011465016

All work relating to a Vestas wind turbine, including work methods and practices, employee
training and protective measures, and use of tools and equipment, shall be in accordance with
the requirements of the applicable governmental and private occupational safety and health
codes and standards. Employers engaged in such work are also required to be familiar with and
comply with the wind turbine-specific ‘Safety regulations for operators and technicians’ manual
for the relevant wind turbine type. Vestas shall not be responsible for any liabilities arising from
failure to comply with such requirements. Vestas reserves the right to inspect such work to
ascertain such compliance.
The service technician must read and understand the PPE sheets for each of the chemicals used
or work done in this instruction. The PPE sheets describe the correct personal protective
equipment to wear for the specific work. If in doubt about the PPE requirements for the work,
contact the site responsible or the line manager and confirm the correct procedure before starting

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the work.
For chemicals that are not specified with accurate name and item no., contact the local site-
responsible person for information about PPE and other safety instructions related to the use of
the chemical.

2.
2 Educational requirements of service technician 0011465014

At least 2 of the service technicians who do work in a wind turbine must be able to prove that they
have a valid GWO basic safety training certificate.
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At least 1 service technician must hold the wind turbine-specific training course certificate for the
wind turbine in question.
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Some tasks require one or more advanced training modules or job-specific training, as described
in the Vestas technical training programme. The person who plans a specific task must make
sure that the service technicians involved have the proper know-how for the completion of that
task.
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3 Abbreviations and technical terms 0021847041

Table 3.1: Abbreviations

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Abbreviation Explanation
CG Centre of gravity
ECC Energy control coordinator
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ERP Enterprise resource planning

GWO The Global Wind Organisation
HV High voltage
LCTU Lightning current transfer unit
LOTO Lockout-tagout
LV Low voltage
PPE Personal protective equipment
SDS Safety data sheet
SPRA Standardised procedure risk assessment
Installation of blades
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Table 3.2: Explanation of terms

Term Explanation
Vestas multi-blade Lifting equipment used to move and install a blade.
installer
T-lifting yoke Lifting equipment used to move and install a blade.

4 Referenced documentation

4.1 Safety documents 0021663554

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Table 4.1: Safety documents

Document no. Title

0001-0410 Personal protective equipment sheets

2.
0004-4159 Standardised procedure risk assessment
0081-2529 Safety regulations for operators and technicians
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4.2 Reference documents 0025324478
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Table 4.2: Reference documents

Document no. Title

Old Vestas multi-blade installer (item no. VT20004292) documents
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0041-5044 User manual and maintenance instruction for multi-blade installer

0042-5385 Use of the Vestas multi-blade installer
0043-2521 Transport, storage, assembly, and disassembly of the Vestas multi-blade
installer
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New Vestas multi-blade installer (item no. VT20022864) documents

0082-9034 User and maintenance manual for multi-blade installer (MBI) VT20022864
20029274 Multi-blade installer for V117*
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20028995 Multi-blade installer for V136*

VT20024509 Multi blade installer for V150
Tool documents
0071-0821 Maintenance and service manual external hydraulic power pack HPU
VT20017830
0078-6519 Use of the lubrication control box
0081-5572 Use of turning gear
0081-5576 Use of yaw and braking box
0082-8752 Transport, storage, assembly, and disassembly of the Vestas multi-blade
installer for V117 and V136 wind turbines
Installation of blades
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Document no. Title

0082-8754 Use of the Vestas multi-blade installer for V117 and V136 wind turbines
0083-3935 Use of multi-blade T-lifting yoke for installation and removal of blades
931734 Pressure charts for hydraulic tightening tools
958576 Use of SWEENEY hydraulic bolt tensioners
959312 Use of SWEENEY and HYTORC hydraulic torque wrenches
959313 Use of PLARAD hydraulic torque wrenches
959314 Use of hydraulic tension tools from ITH GmbH
Other related documents

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0010-8662 Recording of main components
0038-6866 Lifting of blades with 2 cranes
0043-7017 Crane hook height catalogue

2.
0058-4968 Weight, dimensions, and centre of gravity of 67 m blade
0062-5425 SIF for wind turbine installation
0065-3482 Standard service tools
0079-9394 Installation of lightning current transfer unit
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0079-9809 Weight, dimensions, and centre of gravity of 57 m blade
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0079-9836 Grease container for blade bearing
0082-8740 Preparation of blades for installation
0082-8744 Weight, dimensions, and centre of gravity of 73 m blade
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920098 Torque wrench settings

960501 Bolt connections

*) New Vestas multi-blade installer must be used.

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Unless it is specified differently, see 920098 ‘Torque wrench settings’ for information
about bolt types and bolt lubrication, and see 960501 ‘Bolt connections’ for
information about torque values.

5 Purpose
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0021714785

The purpose of this document is to give the procedure for how to install the blades. The blades
are installed horizontally, one at a time.

6 Note 0021910969

Before the installation, the blades must be prepared as given in 0082-8740 ‘Preparation of blades
for installation’. See 0081-5572 ‘Use of turning gear for installation and commissioning’ for the
installation of the turning gear on the gearbox.
This instruction is also applicable for all wind turbines (given in the wind turbine type table) that
have Vestas de-icing blades installed.
Installation of blades
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7 Tools 0021400905

For standard service tools, see 0065-3482 ‘Standard service tools’.

Some tools in this tools list can vary in shape and technical specification from region
to region due to local requirements.
If in doubt, contact your local tools warehouse for tools applicable to your region.
This note may not be applicable for any special tools used in this procedure.

7.1 Lifting equipment

7.1.1 Vestas multi-blade installer 0025324477

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Table 7.1: Tools, old Vestas multi-blade installer for V117 and V136 wind turbines

Item no. Quantity Description

2.
VT20004292 1 ERP: Multi blade installer assembly

Table 7.2: Tools, new Vestas multi-blade installer for V117, V136, and V150 wind turbines

Item no. Quantity Description

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VT20022864 1 ERP: MULTI BLADE INSTALLER ASSY
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20026902 1 ERP: COUNTER WEIGHT KIT 1
20026903 1 ERP: PRESSURE SHOES KIT 2
Cradle kits (blade specific)
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20026905 1 ERP: CRADDLE KIT V150

20027588 1 ERP: CRADDLE KIT V136
20027593 1 ERP: CRADDLE KIT V117
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7.1.2 2-crane lift

Table 7.3: Tools, 2-crane lift

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Item no. Quantity Description

20026981 1 ERP: GA V150 2 CRANE LIFT TOOL KIT
VT20002441 1 ERP: 2 CRANE BLADE LIFT KIT F V117
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7.1.3 Multi-blade T-yoke 0025324475

Table 7.4: Tools, multi-blade T-yoke

Item no. Quantity Description

VT20010833 1 ERP: TAI MB T-YOKE TOOL KIT V117
VT20019614 1 ERP: TAI MBT-YOKE TOOLKIT F V136
VT20025684 1 ERP: TAI MBT-YOKE TOOLKIT F V150

7.1.4 General equipment 0024974021

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Table 7.5: General equipment

Item no. Quantity Description

VT186964 1 ERP: HIGH PRESSURE PUMP 230V

2.
VT189668 1 ERP: HYDRAULIC PUMP VAX12 800BAR
VT189674 1 ERP: OILPUMP 1500B 230V
VT189695 1 ERP: HYDRAULIC PUMP VAX 3,5Z
VT200307 1
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ERP: HUB STEP PLATFORM ASM
VT730101 1 ERP: ELECTRIC IMPACT WRENCH 1/2"
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VT730706 1 ERP: HYDR.HOSE 1500B. 10M
VT730708 1 ERP: HYDR. HOSE DOUBLE 800B. 10M
VT732709 1 ERP: BLADE BAG
VT20017830 1 ERP: EXT HYDR POWER PACK FOR PITCH
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VT70003359 1 ERP: DRILL, ANGLE CRDLS 18V

238349 1 ½" adapter
ERP: ADAP.BITZ FOR ½"SOCKET-1/4" SH
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238421 1 ERP: LOCK RING, IMP SKT 1/2" DRV 17-46MM

238483 1 ERP: IMPACT ADAPTOR 1/2" - 3/4"
883462 1 Static discharge blade kit
ERP: STATIC EL DCHARGE KIT BLADE T2
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2 Guiding rope (length at least 1.5 times hub height)

7.2 Tightening tools 0024861518

Table 7.6: Tools for tightening

Item no. Quantity Description

238349 1 ERP: ADAP.BITZ FOR ½"SOCKET-1/4" SH
238421 1 ERP: LOCK RING, IMP SKT 1/2" DRV 17-46MM
238483 1 ERP: IMPACT ADAPTOR 1/2" - 3/4"
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Item no. Quantity Description

294003 1 ERP: BATTRY DRILLING MACHINE DEWALT
or
VT70003359 1 ERP: DRILL, ANGLE CRDLS 18V
883462 1 ERP: STATIC EL DCHARGE KIT BLADE T2
VT186964 1 ERP: HIGH PRESSURE PUMP 230V
VT189668 1 ERP: HYDRAULIC PUMP VAX12 800BAR
VT189674 1 ERP: OILPUMP 1500B 230V
VT189695 1 ERP: HYDRAULIC PUMP VAX 3,5Z
VT200307 1 ERP: V112 HUB STEP PLATFROM ASM

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VT730101 1 ERP: ELECTRIC IMPACT WRENCH 1/2"
VT730706 1 ERP: HYDR. HOSE 1500B. 10M
VT730708 1 ERP: HYDR. HOSE DOUBLE 800B. 10M

2.
VT732709 1 ERP: BLADE BAG
VT20017830* 1 ERP: EXT HYDR POWER PACK FOR PITCH
2 Guiding rope (length at least 1.5 times hub height)

*) Applicable to both 50 and 60 Hz wind turbines.

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The hydraulic power pack (item no. VT20017830) is an alternative to the hydraulic
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pump (item no. VT200243) and the hydraulic power pack (item no. VT20000034).
The hydraulic power pack (item no. VT20017830) must be used for Ø160 mm pitch
cylinder and the larger pitch cylinders (V136 and larger). For the tools, see
‘Maintenance and service manual external hydraulic power pack HPU VT20017830’
in section ‘Reference documents’.
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7.3 Tools for tightening of the M30 stud bolts 0021681768

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Table 7.7: Tools for tightening of the M30 stud bolts

Item no. Quantity Description

227761 1 Fixed ring spanner, 46 mm
ERP: RING FIXED SPANNER 46MM ACESA
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238422 1 ERP: LOCK RING FOR IMP.SOCKET 3/4"

238458 1 Power top 46 mm - ¾ in., long
ERP: IMPACT SOCKET LONG 46mm 3/4"
VT200243* 1 ERP: HYDR.PUMP F. MANUAL PITCH V112
VT730322 1 Sweeney RSL 2 spanner
ERP: WRENCH, TORQ HYDR 3/4IN
VT730440 1 Tensioning tool for M30 stud bolt
ERP: BOLTTENSIONER M30 HYDRATIGHT
VT738012 2 ERP: GUIDE PIN F. BLADE/HUB
VT20000034† 1 ERP: HYDRAULIC POWER PACK,V112 60HZ
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*) Applicable to V117 50 Hz wind turbines only.

†) Applicable to V117 60 Hz wind turbines only.

7.4 Tools for tightening of the M36 stud bolts 0021684021

Table 7.8: Tools for tightening of the M36 stud bolts

Item no. Quantity Description

290918 1 ERP: POWER TOP 1" 55mm LONG IMPACT
20029112 2 ERP: GUIDE PIN FOR M36 STUD BLADE
VT730323 1 ERP: HYDR.WRENCH RSL4 1" FIRK.

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VT20004551 1 ERP: SCREW NUT M36 1/2in
VT20024712 1 ERP: TENSIONER M36 PL 80-95 AF55

7.5 Electrical equipment

2.
Table 7.9: Electrical equipment d
Item no. Quantity Description
VT20022390 1 ERP: LUBRICATION BOX 3MW 50Hz
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VT20023841 1 ERP: LUBRICATION BOX 3MW 60Hz

8 Spare parts 0011449219

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Table 8.1: Spare parts

Item no. Quantity Description

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None

9 Consumables 0025025390

Table 9.1: Consumables

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Item no. Quantity Description

298205 1 Non-Naphtha corrosion inhibitor
ERP: SUVO BRUN NON NAFTA SPRAY
As necessary Water-absorbing cloth
3 Blade-collar plug

10 Weights 0021684020

The weight and the CG of the blade given in ‘Weight, dimensions, and centre of gravity’ in section
‘Reference documents’ is the transport weight of the blade without installation of the stud bolts.
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The CG is moved approximately 300 mm from the root end of the blade when the stud bolts are
installed in the blade root.

11 Estimated time use 0021681767

The time required to complete this procedure is approximately 1–1.5 hours to install 1 blade.

12 Procedure

12.1 Lockout-tagout start 0011426234

Isolate the part of the wind turbine where you will do the work. Obey the LOTO procedure

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instruction referred to in ‘Safety documents’. If no LOTO procedure instruction is included in
‘Safety documents’, obey the LOTO instruction supplied by the site-ECC.

12.2 To identify the stud bolts at the TC mark 0021729418

2.
1 Use a yellow marker to identify the 2 stud
bolts (1), which are at the TC mark on the
blade.
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2 Identify the stud bolt (1) for the poke yoke

system (blind holes) on the blade.
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12.3 To prepare the hub 0011421070

Risk of slipping because of spilled oil! SPRA ID No. 9.07

• Clean up spilled oil immediately.
• Examine the system for oil leakages.
• Make sure that the work area is free from oil.
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Risk of severe crushing injuries! SPRA ID No. 5.01

• Obey the applicable LOTO procedures.
• Stop the wind turbine to prevent unintended starts and remote operation.
• Apply the brake before you remove the covers.
• Lock the rotor mechanically before you remove the covers.

12.3.1 To put the nacelle and the hub in the correct position 0021684018

Risk of injury because of falling object! SPRA ID No. RW 19.79

• Ensure good two-way communication between the service crane operator in the
nacelle and the service technician by means of two-way radio/mobile phone or

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hand signals.
• The service crane operator and other persons must only use standard signals.
• At all times, only one person at a time must send a signal to the service crane
operator. If more than one signal at a time is given, the operation must be stopped

2.
immediately.
• Where communication between the service crane operator and the service
technician is broken, the lifting operation must stop.
• Make sure that communication devices are fully charged before the lifting
operation.
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Risk of severe crushing injuries! SPRA ID No. 5.09
• Do not enter the hub and do not do any procedures on the hub or nose cone unless
you have done the applicable LOTO and made sure that the pitch system is in a
safe condition.
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• Obey the rules for work at height.

Risk of crashing of the blade into the crane boom

• Do not yaw the nacelle or turn the rotor without continuous signal from banksman.
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• Do notyaw the nacelle or turn the rotor when the crane is in operation or during the
loading of the blade onto the lifting tool.
• Do not yaw the nacelle or turn the rotor parallel with the crane operation.
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• The blades must be installed horizontally on the left-hand side of the nacelle when seen from
the rear end of the nacelle.

1 Operate the lubrication pump for 20 minutes for base lubrication function before you operate
the turning gear. See ‘Use of the lubrication control box’ in section ‘Reference documents’.

2 Install the yaw box and the turning gear onto the nacelle. See ‘Use of yaw and braking box’
and ‘Use of turning gear’ in section ‘Reference documents’.
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3 Yaw the nacelle to the correct angle in relation to the crane.

4 Visually examine the sight glass on the

gearbox to make sure that the gearbox is in
the WET SUMP mode.

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2.
Risk of severe crushing injuries! SPRA ID No. 5.04
• Keep all body parts, clothing, accessories, and PPE clear of the rotating parts.
• Remove the full-body harness before you do work on the rotating parts.
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Risk of severe crushing injuries! SPRA ID No. 4.08
• Do not operate the turning gear without all hydraulic motors installed.
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Risk of damaging the rotor locking system!
• Do not operate the turning gear continuously while the rotor lock is applied.
• Carefully turn the high-speed shaft a quarter of a turn counterclockwise to release
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the load on the rotor locking mandrels before you unlock the rotor.
• Do a visually check to see that all 3 locking mandrels are clear of the hub before
you turn the rotor.
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5 Operate the turning gear for 5 minutes to lubricate the gearbox.

6 Turn the hub with the turning gear until one of the blade bearings is put in the vertical
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position on the left-hand side (controller side) of the nacelle.

7 If the hub access door is installed, open the hub access door from the nacelle.

a Lock the bolt lock in the hydraulic pump of the rotor lock system.
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• The Ab key (1) is released

automatically.

b Put the Ab key (1) into the bolt lock for

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the rotor lock and lock the rotor lock
system.

2.
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• The Ac key (1) is released
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automatically.
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c Remove the Ac key (1) from the bolt

lock for the rotor lock.
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d Put the Ac key (1) in the interlock to get

access to the hub door.

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8 Apply the rotor lock before you go into the hub.

2.
9 Keep the rotor in the locked position when you install the blade.

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Risk of skin and eye damage and injuries from contact with high-pressure air or
fluids! SPRA ID No. 4.10
• Use the necessary PPE which includes protective goggles and cut-resistant
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gloves.
• Obey the appropriate procedures for release of the pressure in the system before
you open any system connections or ports.
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Risk of exposure to hazardous substances and mixtures hydraulic oil! SPRA ID

No. 2.02
• See the 'Installation and service data', the ‘Lubrication chart’, or the service
inspection report of the wind turbine to determine the hydraulic oil type.
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• Use the necessary PPE that is given in sheet G. Read and obey the related SDS.

10 Open the -QM1 drain valve (1) on the

distributor block.
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The distributor block is installed adjacent to the hub controller.

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11 Open the -QM2 drain valve (1) on the pitch

blocks.

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12 Visually examine to make sure that the
-QM31 ball valve (1) is in the ‘Hub service’
position on the pitch block.

2.
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The -QM31 ball valve must be closed before you connect the external pitch
pump.
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13 Install the hoses from the external pitch pump.

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a Release the hydraulic pressure in the hydraulic system behind the couplings if the
hoses to the external pitch pump cannot be installed.

b Use the mini-mesh test hose to release the hydraulic pressure in the pitch block.
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c Put one end of the mini-mesh test hose in a bottle to keep the oil.

d Connect the other end of the mini-mesh test hose to connection XM3, which drains the
hydraulic pressure behind connection XM4.

When the hydraulic pressure is released, there must be a firm grip on the 2
ends of the mini-mesh test hose. A sudden release of hydraulic pressure
can cause the mini-mesh test hose to move or come out from the bottle.
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e Remove the mini-mesh test hose from connection XM3 when all the hydraulic
pressure is released.

Risk of severe crushing injuries! SPRA ID No. 5.07

• Obey the applicable LOTO procedures.
• Lock the rotor mechanically.
• Apply the pitch lock.

14 Connect the hoses from the external pitch

pump to the quick-acting coupling.

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The quick-acting coupling has
the marks XM6 (1) and XM4 (2)
on the pitch blocks.

2.
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15 Turn the bolt (1) from the parking position to
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the centre of the blade lock (2).
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16 Tighten the bolt (1) in the middle of the blade

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lock until the blade lock (2) is sufficiently

lifted to move the blade.
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17 Do a functionality test of the external pitch

pump (1) before the installation of the blade.

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12.4 To use the Vestas multi-blade installer 0021723953

Risk of being struck by falling objects! SPRA ID No. 19.20

2.
• It is strictly prohibited to stay or work below a suspended load or in a drop zone.
The only exception to this rule is when you do approved work in a Vestas-defined
protective zone.
• Remove ice and snow from the blade surface before you start the lifting operation.
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• Remove ice and snow from gurney flaps before you start the lifting operation.
• Remove water accumulated in the gurney flaps when there is a risk of
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temperatures below 0°C.

Risk of suspended load failure! SPRA ID No. 19.17

• It is strictly prohibited to stay or work below a suspended load or in a drop zone.
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The only exception to this rule is when you do approved work in a Vestas-defined
protective zone.
• Do not use the Vestas multi-blade installer unless you have made sure that all bolts
and other attachments on the installer are tightened and checked.
pp
A
Installation of blades
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Risk of suspended load failure! SPRA ID No. 19.01

• It is strictly prohibited to stay or work below a suspended load or in a drop zone.
The only exception to this rule is when you do approved work in a Vestas-defined
protective zone.
• A lifting plan must be made and communicated to all personnel before the lifting
operation.
• Lifting operations are not allowed when the wind speed is higher than the maximum
value in accordance with the wind speed guidelines for the task. See the lifting
plan.
• Only trained and qualified service technicians and crane operators are allowed to
do the lifting operation.
• Make sure that an examination and test of the crane is done in accordance with

10
local requirements.
• Use only certified lifting equipment and fully examine the lifting equipment before it
is used.
• All hoists and lifting equipment must be formally examined before it is used.

2.
• Obey the correct slinging arrangement and lifting procedures.
• Use the lifting equipment that is approved for the specific task.
• Use guiding ropes when situations are made dangerous by the rotation or
uncontrolled movement of a load.
d
• Obey the precautions to avoid entanglement when you attach or detach the load.
ve
Risk of suspended load failure! SPRA ID No. 19.03
• Do not stay or work below a suspended load.
• Each guiding rope must be held by a service technician to control the movement of
the suspended load, if necessary.
ro

• Guiding ropes must be actively held and monitored by service technicians during
the lifting operation. The guiding ropes may NOT be tied up to stationary, movable,
or other equivalent, uncontrolled equipment.
• Guiding rope service technicians must be clear of the drop zone.
pp

• Locations for the guiding rope teams must be approved by the crane operator or
site supervisor.
• Guiding ropes can be wound to a maximum of 180° around a solid object. The solid
object must be smooth and free of possible rope entrapments that can prevent the
A

movement of the guiding rope.

Installation of blades
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Risk of damage to the rubber surface of the Vestas multi-blade installer during
the mandatory preparation!
• Do not work or stand directly on the Vestas multi-blade installer rubber parts.
• Never expose the rubber surface of the Vestas multi-blade installer to oil, sand,
mud, and/or other contaminating materials.
• Use a suitable water-absorbing cloth to wipe the surface of the Vestas multi-blade
installer and the blade to ensure dry and clean contact surfaces.
• Always keep the Vestas multi-blade installer rubber parts covered by means of, for
example, a plastic cover when the Vestas multi-blade installer is stored, when not
in use, or during preparation of the blade and the Vestas multi-blade installer for
installation.

10
Preparation of the Vestas multi-blade installer in temperatures below 5 degrees
• Never use a Vestas multi-blade installer exposed to ice and snow.
• Ensure that the rubber surface of the Vestas multi-blade installer is clean and free
from ice and snow.

2.
• Ensure that the surface of the Vestas multi-blade installer and the surface of the
blade are dry and free from ice. Use heating blankets or fan heaters to ensure that
the surfaces are dry.

Mandatory preparation of the blade prior to handling the blade by the Vestas
multi-blade installer
d
• Do not expose the lifting area on the blade to oil, sand, mud, and/or other
ve
contaminating materials.
• Remove all oil, sand, mud, and/or other contaminating materials from the lifting
area (centre of gravity) underneath the blade where the Vestas multi-blade installer
makes contact. This area must be dry and free from ice and other impurities. Use a
fan heater to dry the blade surface.
ro

Preparation of the blade prior to handling the blade by the Vestas multi-blade
installer in temperatures below 5 degrees
• Do not handle a blade by use of the Vestas multi-blade installer if the blade is
pp

exposed to snow and/or ice

• Remove all snow and ice on the entire blade surface prior to lifting. The snow and
ice might change the centre of gravity.
• Remove ice, snow, and other impurities from the lifting area (centre of gravity)
A

underneath the blade where the Vestas multi-blade installer makes contact. This
area must be dry and free from ice. Use a fan heater to dry the blade surface.

Positioning the Vestas multi-blade nstaller on the blade!

• Do not expect the CG marking underneath the blade to be the installation CG.
• Always follow the instructions when positioning the Vestas multi-blade installer on
the blade.
• Always use the CG marking as an indicative reference when positioning the Vestas
multi-blade installer.
• Perform a test lift to verify the CG. (Approx. 1 m from the ground).
• Adjust the position of the Vestas multi-blade installer until the lift is in full balance.
Installation of blades
Document no.: 0081-5575 V02 · Class: RESTRICTED · Type: T09 Page 22 of 58

• Assemble and use the old Vestas multi-blade installer (item no. VT20004292). See
‘Transport, storage, assembly, and disassembly of Vestas multi-blade installer’ and ‘Use of
the Vestas multi-blade installer’ in section ‘Reference documents’.

• Assemble and use the new Vestas multi-blade installer (item no. VT20022864). See ‘User
and maintenance manual for multi-blade installer’ in section ‘Reference documents’.

Each blade can have minor weight and CG variations for different reasons such as
added stud bolts (approximately 300 mm variation).

1 Do a check of the CG on the blade.

10
a Do a check of the CG mark (1) on the
blade for the old Vestas multi-blade
installer (item no. VT20004292).

2.
d
ve
The CG mark is in the middle of the blade on the windward side, 1300 mm
from the leading edge, and in a radial distance according to the related
‘Weight, dimensions and centre of gravity’ in section ‘Reference
documents’.
ro

b Do a check of the CG on the blade for the new Vestas multi-blade installer (item no.
VT20022864). See section 4.2 Reference documents, page 6 for the related GA
drawings.
pp

2 Use water-absorbing cloth to clean the contact surface on the blade.

A

3 Remove the cover for the Vestas multi-blade installer from the blade before you attach the
Vestas multi-blade installer to the blade.

4 Examine the saddles for wear, damage, dirt, oil, chemicals, grease, silt, and such like.

5 Use water-absorbing cloth to clean the saddles.

Installation of blades
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a Examine the lifting equipment, contact surfaces, and all the blades for ice and snow
when the temperature around the hub height is below 5°C.

The snow and ice must be removed from the contact surfaces. Heating
equipment must be used until the snow and ice are melted. Water-absorbing
cloth must be used to remove the melted snow and ice 1 hour before you use the
Vestas multi-blade installer.

6 Examine the quality of the friction rubber after the friction rubber is cleaned.

10
The friction rubber must be replaced if there is contamination like mud, silt, or
other damage that can reduce the friction.

2.
7 Attach the guiding ropes (1) to the end of the
arms (2) of the Vestas multi-blade installer. d
ve
ro

8 Carefully move the Vestas multi-blade

installer (1) to the CG position on the blade.
pp
A
Installation of blades
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Damage to the blade tip!

• Do not put the blade bag or a guiding rope over the tip of the blade. The minimum
distance must be 1 m from the tip.
• Obey the standard procedure described in the instruction.

9 Attach the safety sliding device to the blade.

See ‘Use of the Vestas multi-blade installer’
for the old Vestas multi-blade installer (item
no. VT20004292) and ‘User and
maintenance manual for multi-blade installer’
for the new Vestas multi-blade installer (item
no. VT20022864) in section ‘Reference

10
documents’.

2.
10 Do a CG test of the lift (approximately 1 m from the ground) before the installation of the
blade. d
a Put the crane hook straight above the Vestas multi-blade installer in the CG position.
ve

b Do a check of the blade CG in the Vestas multi-blade installer.

ro

Root end and tip end of the blade must be lifted at the same time.

c Put the vertical angle of the blade-root end close to 90° to do a safe installation of the
pp

blade.

12.5 To use the T-lifting yoke 0021723952

A

See ‘Use of multi-blade T-lifting yoke for installation and removal of blades’ in section
‘Reference documents’ for more information about how to use the T-lifting yoke to
install the blades.

Risk of damage to the blade tip!

• Do not place the blade bag or any guiding rope over the tip of the blade. The
minimum distance should be 1 m from blade tip.
• Obey the standard procedure given in the instruction.
Installation of blades
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10
2.
d
ve
Figure 12.1: Example of how to handle the blade for installation by use of a T-lifting yoke

12.6 To do a 2-crane lift 0011421086

ro

See ‘Lifting of blades with 2 cranes’ in section ‘Reference documents’ for information about how
to do a 2-crane lift to install the blades.
pp
A
Installation of blades
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10
2.
d
ve
Figure 12.2: Lifting of the blade by use of 2 cranes

12.7 To lift the blade 0011421085

ro

• Make sure that the designated spotter or a banksman is available throughout the procedure
when you do the lifting operation.
pp

• The person must be free from the tag line and must be able to move in the pad except the
drop zone to get the best view of the lifting path.
• The person must call in and out the other service technicians to give signal to the crane
operator as and when necessary.
• Make sure to give un-broken signals to the crane operator all the time.
A

• Make sure to give the communication over a radio in the agreed lifting language.
• Stop the lifting operation if something is not clear or when in doubt.
• Make sure that the nacelle and/or rotor are/is stationary when the crane is in operation.
• Stay available as long as the crane remains boomed up and installation activities are in
progress.
• Make sure that when the crane is boomed up, the nacelle is in manual mode and rotor is
in locked position before you leave the pad.
• Make sure that you do not share the radio channel that is used to send signals at the time of
the blade operation for a different operation.
• Hard stand talk:
Installation of blades
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• Conduct a hard stand talk with all the participants before you involve in lifting the blade.
• Agree upon common lifting language.
• Know the person at each end of the communication.
• Communicate the pad-specific risks and guideline.
• It is mandatory to have an approved and signed-off lifting plan before each lifting operation.
• In addition to this, a limit of maximum lifting speed for each individual lift is required.

• It is mandatory to have an approved and signed-off lifting plan before each lifting operation.
• In addition to this, a limit of maximum lifting speed for each individual lift is necessary.
Installation of blades

10
It is not necessary to install all the 3 blades at the same day. Installation of 1 or 2 blades can be
postponed to the next day.
When 1 or 2 blades are installed on the next day, keep the blade positions as follows:

• If only 1 blade is installed : Park the blade along the tower.

2.
• If 2 blades are installed : Park the 2 blades in position downwards bunny ears.

Risk of suspended load failure! SPRA ID No. 19.02

• It is strictly prohibited to stay or work below a suspended load or in a drop zone.
d
The only exception to this rule is when you do approved work in a Vestas-defined
protective zone.
ve
Observe wind speeds!
• The crane operator must give the maximum operational wind speed based on the
calculation made for the specific crane type/configuration and the values given in
0043-7017 ‘Crane hook height catalogue’.
ro

• Make sure that the radio communication between crane operator, nacelle personnel, and the
ground personnel who holds the guiding ropes.
•
pp

Applicable number of educated installation technicians is necessary to control each guiding

rope, according to the wind conditions (at least 2 educated installation technicians are
necessary to control each guiding rope).

It is not permitted to attach guiding ropes to the vehicles and equivalent equipment.
A

1 Carefully hoist the blade up to the necessary hub height.

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2 Guide the blade root (1) carefully into the

blade bearing.

10
If it is estimated to be dangerous to install the blades or if the people involved feel
uncomfortable with the work because of strong wind, the work must be postponed, as
safety has the highest priority.

2.
12.8 To guide the blade into the hub 0021681766

• Two service technicians are necessary to move the blade into the correct position, one
service technician in the hub and the other in the nacelle, next to the main shaft.
d
• The guiding pins must be used to put the blade in the correct position.
ve
Risk of exposure to electric shock! SPRA ID No. 3.10
• Use the earthing connection to discharge the static electricity.
• Use an HV/LV voltage detector to measure zero voltage before you start to do the
ro

work.
• Use certified and correct tools and equipment.
• Use the necessary PPE that is given in PPE sheet 7.
pp

1 Install the discharge cable (1) before you

touch the blade.
A
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2 Make sure that the poke yoke system (blind

holes) between the blade and the hub is
aligned.

10
2.
d
Risk of crushing of body parts! SPRA ID No. RW 19.76
• Keep body parts clear of pinch points.
ve
Risk of installation of blade in incorrect position!
• It is not possible to calibrate the pitch system if the TC marks are incorrectly
aligned.
ro

• Do a check to see that the TC marks are aligned and the blades are installed
correctly.

3 Move the blade to the correct position.

pp
A
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4 Make sure that the TC marks (1) on the

blade and the blade bearing are aligned.

10
Risk of severe crushing injuries! SPRA ID No. 5.11
• Vacate the hub during movement of the pitch system.

a Pitch the blade bearing to align the blade and the blade bearing so that the 2 TC marks

2.
are as near to each other as possible.

b Do a visual check to make sure that the

TC mark (2) on the blade bearing is in-
between the 2 stud bolts (1) with yellow
d
marks.
ve
ro
pp
A
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5 The service technician in the hub must make

sure that the poke yoke system (blind holes)
between the blade and the hub is aligned.

10
2.
6
d
Install some of the nuts on the blade bolts to so that the blade does not slide out.
ve
7 Do the procedure that follows to remove the safety sliding device from the outer side of the
blade root:
ro

a Install a wedge between the blade root and the blade bearing to secure the blade in
the outermost position.
pp

b Attach one end of the rope to the slide-

securing device (1). Secure the other
end of the rope to the spinner.
A
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c Open and remove the shackle (1) from

the rope.

d Remove the outermost part of the

sliding safety sling (1) (DynaOne®

10
sling) from the blade root.

2.
d
e Assemble the innermost and the outermost parts of the slide-securing device again.
ve
• Keep the extended rope in the hub until the clamps on the Vestas multi-blade
installer are released (if there are clamp errors).
ro

f If the clamps on the gripper cannot be opened, attach a rope to the slide-securing
device to reinstall the safety sling to the blade root.

g
pp

When the clamps are open, release the rope.

h When the Vestas multi-blade installer is free of the blade, let the slide-securing device
hang below the Vestas multi-blade installer with the extended rope still attached to the
A

slide-securing device.

The sliding safety device must be removed when the blade is attached to the
blade bearing with a minimum of 1 nut.

The sliding safety device is applicable only when the Vestas multi-blade installer
is used as the lifting tool for the installation of the blades.
Installation of blades
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12.9 To install the washers and the bolts 0011421083

Risk of catastrophic system failure as a result from improper bolt torque! SPRA
ID No. 9.09
• Always make sure that the correct torque is applied.
• Do not identify the bolts with a mark before they are tightened to the correct torque
value.
• When you identify bolts and nuts with marks, make sure that the marking extends
from the top surface, down the side, and onto the mating surface. This in order to
make sure that future inspections can verify that the bolt or nut have not come
loose.

10
1 Attach the step platform (2) to the stiffening
plate (1) of the blade bearing to get access
to the upper part of the blade bearing to
install the washers and the bolts.

2.
d
ve
Risk of breaking loose thread inserts in the blade!
• The thread inserts can break loose if you use large wrenches.
ro

• Do not use electric impact wrenches with a rated output above 400 Nm.

If the washers have a chamfered side, then the chamfered side must face the nut.
The text on the nut must face outwards.
pp

2 Put 1 washer (2) and 1 nut (3) on each stud

bolt (1).
A
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Risk of exposure to a noise level above 80 dB(A) or tool vibrations! SPRA ID

No. 9.03
• Use the necessary PPE that is given in PPE sheet 10.
• Maintain the tools as given in the user manual.
• Examine the noise level in the user manual for the tool.

3 Tighten as many nuts (2) as possible with a

small electric impact wrench (1).

10
2.
If the stud bolts are delta-threaded, lubrication is not necessary.
d
ve
ro
pp
A

Figure 12.3: Delta-threaded stud bolts

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You can find the information on the plate attached to the pallet with the bolts to see if the bolts are
delta-threaded or not. The delta-threaded bolts can have different abbreviations as DT, DSGz,
Delta, and FlZnLnc.

10
2.
d
Figure 12.4: Part list
ve
12.10 To remove the lifting equipment 0024861517

Risk of crashing of the blade into the crane boom

ro

• Do not yaw the nacelle or turn the rotor without continuous signal from banksman.
• Do notyaw the nacelle or turn the rotor when the crane is in operation or during the
loading of the blade onto the lifting tool.
• Do not yaw the nacelle or turn the rotor parallel with the crane operation.
pp

Risk of damaging the blades!

• Make sure that both retaining clamps are fully open before you remove the load
from the crane.
A

• Be careful during the removal of the Vestas multi-blade installer.

• Keep the guiding ropes tight to control the Vestas multi-blade installer.

Risk of fall to the ground! SPRA ID No. 1.09

• Only open the nose cone when the service technicians, who are in the spinner and
the hub, wear personal fall arrest equipment. The personal fall arrest equipment
must be attached to an approved anchor point.

• All the nuts that can be accessed must be tightened before the crane can be removed.
• There must be radio communication between the crane operator, nacelle personnel, and the
ground personnel who holds the guiding ropes.
Installation of blades
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1 Remove one of the hatches in the nose cone

to see the Vestas multi-blade installer and
the crane.

10
• View of the crane and the Vestas multi-
blade installer (1).

2.
d
ve
2 Open the retaining clamps on the Vestas multi-blade installer to deactivate the retaining
device.
ro

3 Remove the load from the crane.

pp

4 Yaw the nacelle or use the crane to get the blade out of the gripper.
A

a Make sure that the blade is free from

the Vestas multi-blade installer (1)
before you yaw the nacelle.
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12.11 To rotate the hub 0021684015

Risk of fall into the blades from open manholes! SPRA ID No. 1.08
• Only remove the manhole covers for the blade bearings when the service
technicians have attached personal fall arrest equipment to an approved anchor
point.
• If there is only one manhole cover in the hub, it must be installed on the blade that
points downwards, before you remove the personal fall arrest equipment.
• Use the manhole cover to secure the opening which points downwards.

1 Install the manhole cover onto the installed blade.

10
2 Remove the bolt that forces the blade lock to
open.

2.
There is a risk of damage to the
blade lock if the bolt is in forced
open position.
d
ve
ro
pp
A

a Keep the bolt in the parking hole.

Risk of severe crushing injuries! SPRA ID No. 5.11

• Vacate the hub during movement of the pitch system.

3 Pitch the blade until the automatic blade lock is engaged.

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4 Remove the hoses from the external pitch pump.

5 Remove tools and loose parts from the hub.

6 Make sure that the gear oil lubrication pump is in operation before the rotor is operated.

10
7 Make sure that the gearbox is in the wet sump mode and then start the lubrication pump.

Risk of damage to the gearbox!

2.
• Do not operate the turning gear without the oil supply to the gearbox. Always
activate the electrical pump before rotating with gearbox.

Risk of damaging the rotor locking system!

d
• Do not operate the turning gear continuously while the rotor lock is applied.
• Carefully turn the high-speed shaft a quarter of a turn counterclockwise to release
ve
the load on the rotor locking mandrels before you unlock the rotor.
• Do a visually check to see that all 3 locking mandrels are clear of the hub before
you turn the rotor.

8 Ask permission from the crane operator

ro

before you turn the hub to the correct

position to prevent collision with the next
blade.
pp
A

a Release the rotor lock.

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9 Turn the hub (1) to the correct position to

install the next blade and apply the rotor
lock.

The first installed blade must

always be turned
counterclockwise and must
always be parked in the 11
o’clock position to decrease the
stress on the turning gear.

10
10 Do steps 1–9 again to install the remaining blades.

2.
12.12 To install the LCTU 0021723951

Risk of exposure to electric shock! SPRA ID No. 3.15

• Use the necessary PPE that is given in PPE sheet 7.
d
• Make sure that the discharge cable is connected before you do work on the LCTU.
• Make sure that the LCTU is fully operational before you remove the discharge
ve
cable.
• If repairs of the LCTU cannot be completed, or if the LCTU is removed for other
reasons, install a jumper cable inside the blade before you remove the discharge
cable.
ro

1 Stop the hub when one of the installed blades points up.
pp

2 Install the LCTU. See ‘Installation of lightning

current transfer unit’ in section ‘Reference
documents’.
A
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12.13 To tighten and tension the stud bolts 0021729415

Risk of severe crushing injuries! SPRA ID No. 5.07

• Obey the applicable LOTO procedures.
• Lock the rotor mechanically.
• Apply the pitch lock.

Risk of catastrophic system failure as a result from improper bolt torque! SPRA

10
ID No. 6.04
• Always make sure that the correct torque is applied.
• Do not identify the bolts with a mark before they are tightened to the correct torque
value.

2.
• When you identify bolts and nuts with marks, make sure that the marking extends
from the top surface, down the side, and onto the mating surface. This in order to
make sure that future inspections can verify that the bolt or nut have not come
loose.

•
d
When all the 3 blades are installed, the stud bolts must be tightened.
ve
1 Turn the hub into a position such that one of the blades points down.
ro

2 Tighten and tension the stud bolts on the blades.

The stud bolts must be tensioned to full torque in less than 24 hours after the
pp

installation of the blade.

A
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Risk of being hit by broken parts or risk of crushing of fingers! SPRA ID No.
9.02
• Use the necessary PPE.
• Make sure that the correct pressure is set on the equipment.
• Keep fingers and other body parts away from operation areas.
• Only use tools/equipment that have the applicable approvals.
• Only qualified persons are allowed to do the work.

Risk of exposure to high-pressure oil or air because of breakage of hoses /

improper clamping! SPRA ID No. 9.01

10
• Do not hold pressure hoses by hand when tools are in operation.
• Use the necessary PPE.
• Do not connect the high-pressure hose before the bolt-tensioning cylinder is
seated and correctly attached to the nut.

2.
• Do a visual check of the system for abnormalities before you start the work.
Include gaskets and seals in the check.
• Make sure that the pressure system is calibrated and examined in intervals by a
qualified person.
d
• Examine the pressure before you start the work.
• Only qualified persons are allowed to do the work.
ve
3 Do the steps that follow to tighten and tension the stud bolts:
ro

a Tighten the stud bolts with a hydraulic torque wrench as given in section 12.13.3 To
tighten the stud bolts with the hydraulic tool, page 44.
pp

b Tension the stud bolts with a hydraulic tensioning tool as given in section 12.14.1 To
adjust the pressure, page 46, to section 12.14.3 To prevent the blade or blade bearing
joints from corrosion, page 50.
A

c Increase the pressure again with the hydraulic tensioning tool to check if the stud bolts
are tightened and tensioned correctly.

12.13.1 To do a check on the length of the protruding thread 0011421096

When the nuts have been pre-tightened, a check of the length of the protruding thread must be
done in order to operate the tensioning tool safely.
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1 Measure the distance from the tool contact

surface to the end of the stud bolts.

10
The distance that must be measured depends on the type of tool used. It can be
the length from the nut to the end of the bolt or it can be the length from the blade
bearing.

2.
2 See the user manual for the specific tensioning tools for acceptance criteria.
d
ve
ro
pp
A
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12.13.2 Sequence to tighten the stud bolts 0011421099

10
2.
d
ve

Figure 12.5: Sequence to tighten the stud bolts

ro

1 Tighten the 9 stud bolts that are illustrated with large numbers.
pp

2 Tighten the stud bolts in the indicated order.

A

3 Tighten 4 stud bolts in a row and then 4 bolts on the opposite side.

4 Build up pressure twice at each bolt as a check. Continue until all stud bolts are tightened.
Installation of blades
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12.13.3 To tighten the stud bolts with the hydraulic tool 0023996964

Risk of exposure to high-pressure oil or air because of breakage of hoses /

improper clamping! SPRA ID No. 9.01
• Do not hold pressure hoses by hand when tools are in operation.
• Use the necessary PPE.
• Do not connect the high-pressure hose before the bolt-tensioning cylinder is seated
and correctly attached to the nut.
• Do a visual check of the system for abnormalities before you start the work. Include
gaskets and seals in the check.
• Make sure that the pressure system is calibrated and examined in intervals by a
qualified person.

10
• Examine the pressure before you start the work.
• Only qualified persons are allowed to do the work.

2.
Risk of being hit by broken parts or risk of crushing of fingers! SPRA ID No. 9.02
• Use the necessary PPE.
• Make sure that the correct pressure is set on the equipment.
• Keep fingers and other body parts away from operation areas.
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• Only use tools/equipment that have the applicable approvals.
• Only qualified persons are allowed to do the work.
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See the work instructions that follow to use the hydraulic torque wrenches:
959312 ‘Use of SWEENEY and HYTORC hydraulic torque wrenches’
959313 ‘Use of PLARAD hydraulic torque wrenches’
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958576 ‘Use of SWEENEY hydraulic bolt tensioners’

959314 ‘Use of hydraulic tension tool from ITH’.
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1 Adjust the tightening tool to apply torque. See 960501 ‘Bolt connections’ for information
about torque values.
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2 Tighten all the stud bolts with a hydraulic torque wrench (for example Sweeney RSL 2).
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3 Tighten the bolts (1) in the sequence as

described in section 12.13.2 Sequence to
tighten the stud bolts, page 43.

10
4 Be careful not to damage the thread on the
stud bolts with the backstop for the hydraulic
tool.

For the M36 bolts there is a risk

2.
of damage to the thread. An
additional socket can be used to
protect the thread. d
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12.14 To tension the stud bolts

12.14.1 To adjust the pressure 0011421095

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2.
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Figure 12.6: Different types of tensioning tools

1 ½ in. adapter (item no. 238349)

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Adjust the pressure on the pump before you connect the high-pressure hose to the
tensioning tool.
You must know that the different brands of tensioning tools require different
pressures.
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Make sure to use the correct pressure table.

Make sure that the tension tool is not connected to the hose before you adjust the
pump.

1 Push the start switch to start the pump.

2 Turn the pressure adjustment valve until the pressure gauge shows a pressure equivalent to
the value given in 960501 ‘Bolt connections’.
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3 Stop the pump.

When you tighten the remaining bolts, the pressure does not require readjustment
and the hoses do not need to be removed. Pay attention that the pressure setting
does not change.

4 Connect the high-pressure hose between the tensioning tool and the pump.

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12.14.2 To use the hydraulic tensioning tool 0024861516

Risk of eye injury! SPRA ID No. 9.05

• Make sure that there is no oil on the tools.

2.
• Make sure that attachment tools are used.

Risk of damaging the tensioning tool!

• The tool may be damaged if the pump is kept on when the warning ring appears.
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• The piston must be returned before the tensioning tool is installed on a stud bolt.
• The pump must be stopped and the shut-off valve must be opened immediately to
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return the piston if the warning ring appears during pressure build-up.
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Figure 12.7: Warning ring has appeared

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Figure 12.8: Piston has returned

2.
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An angled cordless drill (item no. 294003) with a ½” adapter (item no. 238349) will help you to do
the work.
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Risk of exposure to high-pressure oil if pressure limits are exceeded! SPRA ID

No. 9.04
• Stay clear of the cylinders and pressurised hoses.
• Do not allow the pressure to exceed the predefined pressure.

Risk of exposing tensioning tool and stud bolts to excessive pressure!

• Tensioning tool and stud bolts can break if exposed to excessive pressure.
• Do not exceed the pressure/tension given in 960501 ‘Bolt connections’.
• Remember to remove the hose from the tensioning tool if the pressure has to be
adjusted during the work.

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• Make sure that the pressure setting of the pump does not change during the work.

It can be necessary to wriggle the tool to make it hold the nuts correctly.

2.
1 Put the hydraulic tensioning tool (1) on the
stud bolt. d
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a Tighten the tool until it is in contact with the supporting surface.

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b Make sure that the piston has returned completely.

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2 Press (and hold) the start button on the

pump until the correct pressure is reached.
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3 Torque the nuts to 30 Nm with a torque wrench when the pump is idle.

4 Make sure that the nut is in contact with the washer.

5 Open the shut-off valve to release the pressure.

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6 Wait for 10 seconds for the pressure to build up.

7 Torque the nut on the stud bolt again to 30 Nm.

2.
The nut must not turn during this check.
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8 Remove the tool (3) and make a mark on the
stud bolt (1) with a pen (2).
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9 Tighten the remaining bolts in the sequence as given in section 12.13.2 Sequence to tighten
the stud bolts, page 43.
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12.14.3 To prevent the blade or blade bearing joints from corrosion 0025025388

Risk of exposure to hazardous substances and mixtures, Suvo Non Naphtha,

brown! SPRA ID No. 2.02
• Toxic to aquatic organisms. May cause long-term adverse effects in the aquatic
environment. Irritates skin.
• Use the necessary PPE that is given in sheet G. Read and obey the related SDS.
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1 Apply Non Naphtha (item no. 298205) or a

similar corrosion inhibitor to the gap between
the blade and the blade bearing from the
inner side of the blade.

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2 Clean the unwanted corrosion inhibitor.

2.
12.15 To install the grease container for the blade bearings 0021847040

1 See ‘Grease container for blade bearing’ in section ‘Reference documents’ to install the
grease containers on the blade bearings.
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12.16 To remove the safety wire in the hub 0011421091
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The anchor point must not be removed during the removal of the safety wire and
shackle.
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1 Remove the shackle and safety wire (1) and

put them in storage in the nacelle after all
blades are installed.
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2 Remove the manual blade-locking pin (1)

and put it in the storage in the nacelle after
all blades are installed.

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13 To install the covers 0021723950

1 Install the 2 steel brackets (1) in the roof with

the 4 x M8x25 bolts.

2.
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a Do not tighten the bolts completely.

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2 Install the middle bracket (1) with the 4 x

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M8x25 bolts.
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a Torque the bolts to 19 Nm.

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3 Install the 2 bolts (1) to the bracket in each

side to hang the covers.

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4 Install the large cover (2) on the 2 bolts (1).

2.
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5 Put the angle bracket to the side of the

cover. Use the M8x25 bolt (1) and M10x25
nut (2), and the earth braid cable (3).

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2.
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6 Install the lower cover (1) in the 2 sides of

the angle bracket.

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2.
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7 Use the M6x30 screws to install the hatch (1)

for the hub access.
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8 Use the 4 x M5x20 bolts and 2 carriage bolts to install each barrell bolts.

9 Install the 2 barrell bolts (1).

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a

2.
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Use the 4 x M5x20 bolts and 2 carriage bolts to install each barrell bolts
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10 Remove the hatch interlock part (1) from the
rotor lock.
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11 Use M5x40 bolts to install the 2 hatch

interlock parts on the plate and hatch.
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12 Install the eye fixation (1) for the interlock

key wire on the panel.

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13 Install the 3 covers (1), (2), and (3) around
the main shaft.

2.
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13.1 End of installation 0020242483

Risk of crashing the blade into crane boom!

• Do not turn the nacelle to Auto yaw when the crane remain boomed up.

1 Keep the blade in the STOP position.

2 Make sure that the blade lock is engaged and not manually lift.

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13.2 Lockout-tagout end 0011426243

2.
Risk of exposure to electric shock, arcing, flashover, fire, and explosion! SPRA
ID No. 3.28
• Do not remove LOTO devices or restore energy if the work area is not clean of non-
essential items which may accidentally have been dropped during work. (Tools,
screws, washers, cable cores, and such like).
d
• Inspect the work area to make sure that any of the above items are removed.
• Dropped items may cause severe arc blasts, short circuits, and injuries if they are
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not removed before energisation.

Energise again or restore power to the part of the wind turbine where you have done the work.
Obey the LOTO procedure instruction referred to in ‘Safety documents’ or the LOTO instruction
supplied by the site-ECC.
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14 To complete the procedure 0021723949

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1 Fill the service inspection form for wind turbine installation. See section 4.2 Reference
documents, page 6, for the related document.
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2 Fill ‘Recording of main components’ in section ‘Reference documents’.

3 Fill ‘SIF for wind turbine installation’ in section ‘Reference documents’.