2030290EN 00 Docx 2030290EN 0 Disassembly Instructions D4K N149 NV06

Classification: Internal Purpose
Doc.: 2030290EN
DC – INSTRUCTIONS AND MANUALS
Rev.: 00
DISASSEMBLY INSTRUCTIONS
Page: 1 / 134
Nordex Delta4000 N149 NV06
- Translation of the original document (2030290DE, rev. 00) -
This is a translation from German. In case of doubt, the German text shall prevail.
Language: EN – English
Department: Engineering/CPS
Done Reviewed Approved
01-11-2022 01-11-2022 01-11-2022
© 2022 NORDEX GROUP. All rights reserved.

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DISASSEMBLY INSTRUCTIONS Page: 2 / 134
This document, including any presentation of its contents in whole or in part, is the intellectual
property of Nordex Energy SE & Co. KG. The information contained in this document is
intended exclusively for Nordex employees and employees of trusted partners and
subcontractors of Nordex Energy SE & Co. KG, Nordex SE and their affiliated companies as
defined in section 15 et seq. of the German Stock Corporation Act (AktG) and must never
(not even in extracts) be disclosed to third parties.
All rights reserved.
Any disclosure, duplication, translation or other use of this document or parts thereof,
regardless if in printed, handwritten, electronic or other form, without the explicit approval of
Nordex Energy SE & Co. KG is prohibited.
 2022 Nordex Energy SE & Co. KG, Hamburg
Manufacturer’s address as per Machinery Directive:
Nordex Energy SE & Co. KG
Langenhorner Chaussee 600
22419 Hamburg
Germany
Tel: +49 (0)40 300 30 -1000
Fax: +49 (0)40 300 30 -1101
info@nordex-online.com
http://www.nordex-online.com
Please refer to the last page for document information!

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Validity
Product series /
Product Tower
turbine class
Delta4000 N149/4.X TCS164 (NV06)

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Revision index
This revision index is a translation of the revision index in the source document.
Rev. Date Author Reason for revision / chapter AST
00 2022-10-07 J. Pape/Intec New revision 25778

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Table of contents
1 Introduction to these instructions 10
1.1 Scope 10
1.2 Target group 10
1.3 Signs and symbols used 11
1.4 Design of the warning notes 12
1.4.1 Warning notes 12
1.4.2 Warning levels 12
1.5 Directions 13
1.6 Abbreviations 13
1.7 Applicable documents 14
1.7.1 E-numbers 14
2 Safety information 15
2.1 General safety instructions 15
2.2 Wind turbine safety devices 15
2.3 Access to the WT 16
2.4 Personal protective equipment 16
2.5 Working on the wind turbine 16
2.5.1 Preventing electric shock from electrostatic charge 16
2.5.2 Preventing electric shock during thunderstorms 16
2.5.3 Preventing falls when working on the wind turbine 17
2.5.4 Working on and inside the rotor hub safely 17
2.5.5 Working on the drive train safely 18
2.5.6 Working safely with high-stress screws 18
2.5.7 Protection against falling objects 18
2.5.8 Using the crane safely on the WT 19
2.5.9 Wind speed 20
2.5.10 Insects and arachnids 21
2.6 Safe handling of hazardous substances/operating materials 21
3 Pre paring for disassembly 25
3.1 Providing the lifting tackle 25
3.2 Preparing the WT 25
3.2.1 Required securements switched on 25

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3.2.2 Disconnecting transformer 27
3.2.3 Disconnecting cable connection MV switchgear 27
3.2.5 Establishing the portable power supply 28
3.2.6 Assembling and positioning transport frames 29
3.2.6.2 Transport frame – rotor hub 29
3.2.7 Setting the pitch tower damping 30
3.3 Bringing devices, tools and materials to the nacelle 32
3.4 Removing the coupling contact protection 32
3.5 Disassembling the slip ring unit 34
3.5.1 Removing the slip ring cable 34
3.5.2 Disassembling the slip ring unit 34
3.6 Disassembling the generator coupling 36
3.7 Installing the turning drive in the nacelle 38
3.8 Disconnecting the MV cables 38
3.8.1 Disconnecting MV cable from MV switchgear 39
3.8.2 Disconnecting MV cable from transformer 40
3.8.3 Securing MV and supply cables 41

3.8.4 Disconnecting the MV and supply cables 43
3.9 Removing the MV switchgear 44
3.9.1 Assembling substructure and electrical winch 45
3.9.3 Disconnecting control and signal cables 47
3.10 Switching off pitch battery voltage 48
3.11 Setting the pitch gearbox lock 48
3.12 Removing the pitch gearbox lock 49
3.13 Decommissioning the limit switch 50

3.14 Connecting supply voltage 51
3.15 Activating service mode 52
3.16 Removing the rotor lock disk cover 53
3.16.1 Removing the cover plates 53
3.16.2 Disassembling the frame 55
3.17 Disassembling cable and cable guide rotor blade 56
4 Rotor blades 57
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4.1 Preparing the rotor blade assembly 57
4.1.1 Safety measures required if rotor blade disassembly is interrupted 57
4.1.2 Aligning the nacelle to the crane 58
4.1.3 NR 74.5 Preparing rotor blade bolts 58
4.1.4 Bringing the rotor blade into a horizontal position 59
4.1.5 Attaching the guide ropes to the rotor blade 60
4.2 Removing the rotor blades 62
4.2.1 Attaching the rotor blade to the crane 62
4.2.2 NR74.5 Removing screw connections 63
4.2.3 Lowering the rotor blade 64
4.2.4 Disengaging the rotor lock 65
5 Rotor hub 66
5.1 Marking screw connections for disassembly position 66
5.2 Disassembling unmarked screw connections 67
5.3 Removing the service hatch 68
5.4 Securing the service hatch 69
5.5 Assembling the LLA rotor hub 70
5.6 Attaching the rotor hub and lifting the load 71

5.7 Disassembling marked screw connections 71
5.8 Lowering, rotating and setting down the rotor hub 73
5.9 Disassembling the LLA rotor hub 74
5.10 Removing rotation and storage rack 75
5.11 Disassembling the spinner 75
5.11.1 Removing the spinner from the rotor hub 75
5.11.2 Removing the rescue hatch 77
5.11.3 Opening the mounting holes on the rotor hub 77
5.11.4 Removing spinner segments 2 and 3 78

5.11.5 Attaching spinner segment 2 to the crane 78
5.11.6 Removing supporting structure 79
5.11.7 Removing spinner segment 1 from supporting structure 79
5.11.8 Attaching spinner segment 1 to the crane 80
5.11.9 Removing the support structure from the rotor hub 80
5.12 Preparing turning drive for disassembly 81
6 Drive train 82
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6.1 Preparing disassembly of the drive train 82
6.1.1 Disconnecting the electrical connections of the drive train 82
6.1.2 Disassembling ALU rotor bearing lines 83
6.1.3 Disassembling the water cooler of the plate-type heat exchanger 83
6.1.4 Disconnecting the hydraulic system 84
6.2 Removing the drive train 86
6.2.1 Disassembling the M36 load rings at the rotor lock disk 86
6.2.2 Disassembling ALU rotor bearing lines 87
6.2.3 Removing the guard of the rotor shaft 90
6.2.4 Removing the nacelle roof 91
6.2.5 Attaching the drive train to the crane 92
6.2.6 Removing the drive train 95
6.2.7 Removing the supply and signal lines of the Bottombox 96
6.2.8 Removing supply and signal cables 97
7 Nacelle 98
7.1 Preparing the removal of the nacelle 98
7.1.1 Preparing the depositing space for the nacelle 98
7.1.2 Aligning the nacelle 98

7.2 Attaching the nacelle to the crane 99
7.2.1 Attaching the guide ropes 100
7.2.2 Attaching the nacelle to the crane 102
7.3 Disassembling the nacelle 103
7.3.1 Disassembling the nacelle 103
7.3.2 Removing the bottom ladder section 105
7.3.3 Take off the nacelle 105
8 Removing the cooler 106
8.1 Preparatory measures 106

8.2 Draining the cooling water 106
8.3 Disassembling the cooling system frame 108
8.4 Removing wind measuring mast and lightning protection bracket 109
9 Options 110
10 Precast conc rete hybrid tower 111
10.1 TCS tower: Downtimes during removal 111
10.2 TCS tower: Tower screw connection tightening torques 113

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11 Top towe r sections 114
11.1 Removing the service lift 114
11.1.1 Securing service lift in the tower base 115
11.1.2 Removing steel ropes and lift cables 116
11.2 Removing the top section 117
11.2.1 Attaching a tower section to the crane 118
11.2.2 Preparing the top section for disassembly 120
11.2.3 Releasing and removing the tower screw connections 121
11.2.4 Setting down top section and store safely 121
12 TCS towe r: Tower base 122
12.1 Disconnecting the nacelle supply cable 122
12.2 Disconnecting the cables at the tower flange transition 122
12.3 Disconnecting wire mesh cable tray from steel adapter 123
12.4 Disassembling tower base installations 123
13 Final work 124
13.1 Transporting and storing operating materials/hazardous substances 124
13.2 Removing Nordex equipment and the substation 124
14 Appendix 125
14.1 Tools 125
14.2 Weights 127
14.3 Technical data 128

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1 Introduction to these instructions
1.1 Scope
This document describes the tasks for the disassembly of all modules of a Delta4000 product
series wind turbine (WT). A listing of the applicable tower types can be found on page I under
the “Validity” table. The work is listed in a sequence that makes sense technologically.
The following tasks are not described:
 Standard processes
 Disassembly of modules into their components
 Transport/removal
 Waste disposal
 Removing the foundation and access roads
 Erection/removal of other buildings that are part of the wind farm
 Disassembly of WT variants
 Disassembly of optional equipment
Deviations from the described disassembly process occur, e.g., in the following cases:
 WT with customer-specific special solutions
 WTs as prototypes and pilot series versions
In these cases, contact Nordex beforehand. Details indicated as “TBD” had not yet been
defined at the date of creating these instructions and will only be added during a later revision.
1.2 Target group
Requirements for specialized personnel working on the wind turbine:
 Training, instructions and commissioning of intended work
 Proof of regular participation in trainings regarding descending devices and first

aid training
 Physical fitness
 Valid certificate for working at heights
Requirements for mechanics who carry out disassembly tasks on the wind turbine:
 Torque and tensioning tool training for high-stress screws

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Mechanics using torque and tensioning tools to work on high-stress screws must have
experience with the particular components, e.g. through participating in a specific training on
the wind turbine.
Activities involving cranes are only to be carried out and supervised by trained personnel.
The crane operator is responsible for all crane work being carried out.
Specific tasks require additional certificates or qualification. These are listed at the beginning
of each chapter where applicable.
1.3 Signs and symbols used

Sign/
Meaning
symbol
 Prerequisite
 A task to be carried out with no specific order
1. Sequential instructions
2. Pay attention to the specific order!
 Result of a task
 List with no specific order
− Subitem of tasks or lists
Additional information, notes and hints
Reference to information in other documents
Position in which an action is carried out, e.g. on the ground,

station 05, in the nacelle
Personnel carrying out a task, e.g. metal worker, electrically

skilled person
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1.4 Design of the warning notes
1.4.1 Warning notes

The warning notes are arranged according to the safety concept “SAFE”:
 S for “Signalzeichen, Signalwort” (Signal word, warning signal) (DANGER, WARNING,

CAUTION)
 A for “Art und Quelle der Gefahr” (Type and source of the danger)
 F for “Folge” (Consequence)
 E for “Entkommen/Maßnahme” (Escape/Action)
DANGER
Type and source of the danger!
Possible consequences (optional)
 Action
 Action
1.4.2 Warning levels

Warning level Description
DANGER Indicates a hazard with a high level of risk which, if not avoided,
will result in death or serious injury.
WARNING Indicates a hazard with a medium level of risk which, if not avoided,
may result in death or serious injury.
CAUTION Indicates a hazard with a low level of risk which, if not avoided,
may result in minor or moderate injury.
NOTE Indicates a hazard with a low level of risk which, if not avoided,
may result in property damage.
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1.5 Directions
Left, right, forward and back (except rotor blade)
Use the terms “forward”, “back”, “left” and “right” as shown in the figure to indicate directions.
Fig. 1: Directions in the nacelle
L/B left back FWD forward

R/B right back
1.6 Abbreviations
Abbreviation Designation Description
CCV Cold Climate Version Version for cold climate zones
CMS Condition Monitoring System -
LLA Load lifting attachment -
FO cable Fiber optic cable -
LOTO Lock-Out/Tag-Out -
NAC Nacelle -
MV Medium voltage -
MID Middle tower section -
NCV Normal Climate Version Version for moderate climate zones
NFC Near Field Communication -
PPE Personal protective equipment -
Personal fall -
PFPE
protective equipment
TCS Tower concrete steel Precast concrete part
TS Tubular steel tower -

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WT Wind turbine -
WLL Working load limit Load capacity
1.7 Applicable documents
1.7.1 E-numbers
No. Document no._Rev._Document type_Language_Document name
[1] E0004553222_12_QB04_EN_Safety manual_Delta4000
[2] E0004675666_05_QB04_EN_Escape_Route_TCS_Delta4000
[3] E0004875246_01_DC05_EN_Device for rotating and lifting
[4] E0004795547_03_DC05_DE_ Vorrichtung zum Drehen und Ablegen [Device for rotating and storing ]
[5] E0003803884_03_DC05_EN_BA_Cable loop_maintenance platform
[6] E0002893094_04_DC05_DE_ Betriebsanleitung Drehantrieb [Turning drive 4th generation operating

instructions Vers.2]
[7] E0004329816_03_DC02_EN_1151989 + 1153609_MA_TOPlift L+_L+_edition
[8] K0802_058150_DE_03_DC02_ Hailo TOPlift L [MA_Hailo-TOPlift_L_k08g+d]
[9] 2009798IN_02_DC01_1157309_Operating instructions_and_MAL_Mobile working platform_TOPlift_L
[10] E0004887746_01_DC05_EN_Rotor hub_transport device
[11] E0004767904_01_DC05_DE_Transportvorrichtung Maschinenhaus [Nacelle transport device]
[12] E0004932183 Tubular Tower Delta4000 TCS164 NV06
[13] Drive train & turbine compartment work permit (Dri ve train Permit to Work)
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2 Safety information
2.1 General safety instructions

 Safety manual E0004553222 Rules of conduct for, in and on the wind turbine
product series Delta4000
 Safety regulation HSE_12 Work in and around wind turbines
A prerequisite for carrying out the work described here is the compliance with all
international and national safety-relevant standards and specifications and those defined by
Nordex Energy SE & Co. KG.
National health and safety and accident prevention regulations must be complied with.
When handling operating materials and hazardous substances observe:
 the manufacturer information
 the results of the risk assessment for the work to be carried out
Ensure compliance with the safety regulations and rules of conduct described in the
safety manual.
The tasks described in these disassembly instructions must only be carried out by qualified
specialized personnel. A prerequisite is knowledge of the handling of the tools and hoisting
devices, and the personnel must also be informed of the status and background of the project.
Before performing any work on the WT the WT must be stopped manually.
Before working on and in the WT, disconnect the WT from the mains in compliance with the
5 safety rules.
All operating instructions must be made available for on-site inspection.
Always wear safety goggles and safety gloves when working on the hydraulic system or with
hydraulic tools (e.g., hydraulic preloading of screw connections). User instructions and safety
notes of hydraulic tool manufact urers must be observed.
2.2 Wind turbine safety devices

The wind turbine is equipped with safety devices that support safe working during operation
and repair works.
Consult the safety regulation E0004553222 for the positions of the safety devices and
their functions.
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2.3 Access to the WT

The WT is a self-contained electrical operating site. Make sure that only persons who are
authorized to enter can in fact access the WT. The following persons are authorized to access
the WT:
 Electrically skilled persons
 Electrically instructed persons (e.g. mechanic, metal worker)
The following requirements must be complied with when accessing a wind turbine:
 During work in the WT, at least 2 persons must be on site.
 Persons with active implants (e.g. pacemakers, insulin pumps) are not allowed to
access the WT.
 Persons without electrotechnical training may only enter the WT under the supervision
of a person who is authorized to enter.
 Electrically skilled persons with knowledge about the WT instruct persons who enter the
WT for the first time on site.
Take the following measures to avoid getting caught or dragged into rotating parts:
 Remove jewelry.
 Tie long hair back or cover it with a hairnet, scarf or cap.
 Wear tightly fitting work clothes.
2.4 Personal protective equipment

Adequate personal protective equipment (PPE) must be worn in the area of the construction site.
2.5 Working on the wind turbine
2.5.1 Preventing electric shock from electrostatic charge

Air friction leads the wind turbine becoming electrostatically charged. There is a risk o f fatal
injury due to electric shock.
2.5.2 Preventing electric shock during thunderstorms

During thunderstorms, there is a risk of lightning striking the wind turbine. There is a risk of
fatal injury due to electric shock.
When a thunderstorm approaches:
 leave the WT immediately.
 Go to a vehicle or a secure building.

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2.5.3 Preventing falls when working on the wind turbine

When working on the wind turbine, there is a risk of tripping, slipping and falling.
This applies in particular to the following types of work:
 Working on the nacelle roof
 Climbing into the rotor hub
 Several people working at the same time
 Working in confined spaces
There is a risk of fatal injury. Use PPE against falls from a height and secure yourself to the
personal attachment points.
 Stop working on the nacelle roof if the wind speed exceeds 12 m/s at a 10 min
average value.
 Exercise particular caution in the following situations and stop working if necessary:
 Sudden movement of the rotor star
 Vibration of the wind turbine
 Oscillation of the wind turbine due to gusts of wind
 Several disassembly tasks carried out at the same time
2.5.4 Working on and inside the rotor hub safely

There is an increased risk of fatal injury when working on and inside the rotor hub.
 Make sure that the following conditions are complied with when working on the
rotor hub:
 “Drivetrain Permit to Work” must be completed and available.
 The rotor is locked on the rotor shaft.
 The yaw system is locked.
 A person who is able to control the WT is present inside the nacelle.
 The pitch system is secured and de-energized.
When performing tasks where the movement of a rotor blade may put people at risk:
 Disconnect the power supply to the pitch drive for the rotor blade and lock the rotor
blades.
 Disconnect the pitch drive from the power supply immediately after entering the rotor hub.
If it is not possible to disconnect the pitch system from the power supply due to the work to be
carried out, do the following:
 Make sure that no body parts, clothing or harness parts can be pulled in by the pitch
bearings and pinions of the pitch system.
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When performing work inside the rotor hub, carry descender devices for 2 persons.
2.5.5 Working on the drive train safely

There is an increased risk of fatal injury when working on the drive train.
 Make sure that the following conditions are complied with when working on the
drive train:
 “Drivetrain Permit to Work” must be completed and available.
 There is no pitch system error.
 The rotor is locked on the rotor shaft.
 The yaw system is locked.
When performing tasks where the movement of a rotor blade may put people at risk:
 Disconnect the power supply to the pitch drive for the rotor blade and lock the
rotor blades.
If the rotor cannot be locked on the rotor shaft due to the work being performed:
 Lock the rotor with the rotor brake.
2.5.6 Working safely with high-stress screws

High-stress screws absorb extensive forces of the WT and are connected to large components.
Use of the wrong torque and tensioning tools may lead to fatal injuries and fatal accidents due
to incorrectly mounted components.
 Ensure that the tools used are suitable for the required purpose.
 Work with extreme care.
 Proceed particularly carefully in the following situations:
 Rainfall
 Improperly lubricated screws
 Corroded screws
2.5.7 Protection against falling objects

There is a risk of fatal injury from falling objects when working in the vicinity of the wind
turbine.
The following situations are particularly dangerous in this respect:
 Crane work
 Setting up and dismantling a crane
 Sudden gusts of wind
 Several people working at different heights at the same time

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If work is performed at different heights at the same time, e.g., on the nacelle roof and on
the ground:
 Secure any tools, lose components and equipment against falling down.
When working with a crane:
 Block off security zones around the crane.
 Ensure that no-one enters the security zones.
2.5.8 Using the crane safely on the WT
Prior to starting any work, all persons involved must be informed about the country -specific
regulations in writing. A contact person appointed by the site manager will explain the
regulations if there are any questions.
Possible consequences if the regulations for crane work are not complied with:
 Fatal accidents
 Disruption of the infrastructure
 Material and environmental damage
The crane operator is responsible for all crane work being carried out.
Carry out the following tasks before starting to work with the crane:
 Create a complete lifting plan.
 Before you start discuss the necessary steps in a meeting with all persons involved and
assign all tasks clearly.
Always provide sufficient space and time to carry out the crane work.
You must take into account/ensure the following during crane work:
 Use only suitable, approved and certified lifting tackles to hoist components.
 Ensure that nobody is standing under the suspended load when lifting components.
Fence off the required area.
 Maintain an adequate safety distance to prevent injuries from falling objects.
 Keep a close eye on the weather. If a thunderstorm approaches or the wind speed is
too high stop all crane work immediately.
 Use a second crane or guide ropes to prevent that a suspended load swings
uncontrollably causing personal injury or material damage to the tower and nacelle.
 Always position the crane hook precisely vertically above the lifting tackle.
 After crane work, the WT must not be approved again until the crane is safely
stationary or has been lowered.
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2.5.9 Wind speed

Wind is a potential safety hazard when working at heights. The following wind speeds must be
taken into account for the individual disassembly sequence.
The WT may start to vibrate when the wind blows across the nacelle. Therefore, the nacelle
should always be longitudinally aligned with the wind direction.
The rotor blades should be disassembled in one go, i.e. all blades should be disassembled one
after the other without interruption. The drive train and the nacelle are also to be dismantled
in one go.
Corresponding time windows for dismantling the components must be planned in advance.
Achieved disassembly Max. time until the Working on the Measure as

condition disassembly condition WT and staying long as wind
below has been in the WT exceeded
reached
MID section 30 days VWind ≤ 9 Stop

disassembly,
leave WT
Top section 30 days VWind ≤ 7 Stop

disassembly,
leave WT
Nacelle without drive train 30 days VWind ≤ 7 Stop

disassembly,
leave WT
Nacelle with drive train 30 days VWind ≤ 7 Stop

without hub disassembly,
leave WT

and hub disassembly,
leave WT

and hub and disassembly,
one/two/three blades leave WT
VWind describes the 10-minute mean value for the wind speed at the highest point of the
turbine in the respective disassembly condition. On site the 10-minute mean value for the
wind speed can be approximated at the crane jib. If the specified wind speed limits are
exceeded tower vibrations may occur perpendicular to the direction of attack.
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2.5.10 Insects and arachnids

Insects, snakes, or arachnids may find their way into the wind turbine. The animals seek
shelter from the sun or cold temperatures in fissures and grooves in the wind turbine.
Some animals come in swarms (e. g. wasps).
The stings or bites of these animals may result in severe injuries or cause anaphylactic shock.
Wear suitable work and protective clothing to protect yourself against insects, snakes and
arachnids. If necessary, take additional safety measures after consultation with the
local authorities.
Be prepared for an emergency. Plan how to coordinate aid on site and which antidotal
measures must be taken.
2.6 Safe handling of hazardous substances/operating materials

The following hazardous substances/operating materials are used in the wind turbine:
Hazardous
Component Material description Quantity Comment
substance
NCV cooling system Varidos FSK 45 — 60 l —
CCV cooling system Varidos FSK 50 — 60 l —
Generator bearing Klüberplex BEM 41- — 4 kg —

132
Fuchs Urethyn XHD2
Gearbox Fuchs Renolin Unisyn — 20 l —

CLP 320
Shell Omala S5 Wind

320
Hydraulic unit Shell Tellus S4 VX 32 — 1l —
Rotor bearing Klüberplex BEM 41- — approx. 6 —

141 kg
Klüber grease WT
Pitch bearing raceway Fuchs Gleitmo 585K — 5 kg —

plus
Pitch bearing gearing Fuchs Ceplattyn BL — 4 kg —

white
Pitch gearbox Mobil SHC 629 — approx. 6 l —

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Shell Omala S4 GXV

150
Yaw bearing race Fuchs Gleitmo 585 K — 1.2 kg —
Fuchs Gleitmo 585 K

plus
Yaw bearing gearing Fuchs Ceplattyn BL — 2 kg —

white
Yaw gearbox Mobil SHC 629 — approx. —

22 l
Shell Omala S5 Wind
320
Switchgear SF6 gas SF6 gas — —
— LOCTITE Acetic acid, — —

isoalkyl
ester
— Sikaflex — — —
— 2-K color — — —
Observe the safety data sheets for the following products when handling hazardous substances
such as grease, oil, coolant or cleaning fluids:
Hazardous
Material description Safety data sheet
substance
Synthetic oil Mobil SHC 629 14872 MOBIL SHC 629

8027480-XX, 8027481-XX
Shell Omala S5 Wind 320 Shell Omala S5 Wind 320
Shell Omala S4 GXV 150 8021344-XX, 8021347-XX,

8021344-XX Shell Omala S4
Fuchs Renolin Unisyn CLP 320 GXV 150
52949 Fuchs Renolin Unisyn

CLP 320
Grease Mobil SHC Grease 460 WT 15742 MOBIL SHC Grease

460WT
Lubricant Klüberplex BEM 41-132 24006, 28611 Klüberplex BEM

41-132
KlüberplexBEM 41-141
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KlüberKlübergrease WT 20320, 8025343-XX,

8030813-XX Klüberplex BEM
Fuchs Urethyn XHD2 41-141
Fuchs Ceplattyn BL white 20320, 8025343-XX,

8030813-XX Klübergrease WT
8005947-XX Fuchs Urethyn

XHD2
56913, 8012331-XX,
8012332-XX8012331-XX
Fuchs Ceplattyn BL white
Solid lubricant Fuchs Gleitmo 585 K 26302, 26011, 34097, 38239,

43201 Fuchs Gleitmo 585 K
Fuchs Gleitmo 585 K plus
8012330-XX, 8034571-
XX Fuchs Gleitmo 585 K plus
Hydraulic oil Shell Tellus S4 VX 32 26399, 30032, 32530, Shell

Tellus S4 VX 32
Antifreeze and Varidos FSK50 54936 Varidos FSK50

anticorrosive agent
VaridosFSK45 54937 Varidos FSK45
Assess potential health and environmental damage caused by improper handling of the
operating materials/hazardous substances in advance in a risk assessment method statement.
Observe the information of the manufacturers of the operating materials/hazardous

substances. Wear the PPE recommended by t he manufacturer.
Observe legal regulations on the reporting of environmental incidents. Observe the waste
prevention regulations and the regulations on proper waste treatment and waste disposal.
Especially, ensure that substances hazardous to ground water, such as greases, oils, coolants
and solvent-based cleaning fluids, cannot penetrate into the ground, into bodies of water or
into the sewage system. Collect, store and transport these substances to the collection point in
suitable containers to dispose of them professionally.
Perform work in such a manner that no hazardous gases, vapors or dusts are released. If this
is not possible, collect the hazardous substances at the place where they escape or occur and
then dispose of them without endangering people or the environment. If such collection is not
possible, ensure ventilation according to the state of the art.
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Release the pressure from the hydraulic systems before opening them. Then make sure that
no pressure exists.
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3 Preparing for disassembly
3.1 Providing the lifting tackle

Use undamaged, tested and suitable lifting tackle. The required lifting tackle depends on the
wind turbine module to be lifted or lowered.
3.2 Preparing the WT

1. Inform Nordex remote monitoring of the planned WT stop.
2. Connect the emergency power supply
3. Drivetrain Permit to Work must be available for all work.
4. Stop the wind turbine.
5. Preparing the nacelle for work.
 Move the rotor in Y position.
 Engage the rotor brake.
 Engage the rotor lock.
6. Turn off all fuses in the Bottombox and Topbox.
7. Turn on again the fuses needed for dismantling of the WT, see chapter 3.2.1
“Required securements switched on”.
8. Disconnect MV switchgear and secure against reactivation using the documented

procedure for LOTO.
9. Disconnect customer’s ring cables at entrance and exit and secure against reactivation
using the documented procedure for LOTO.
10. Verify that the system is dead, ground and short -circuit.
 The MV transformer is grounded and short -circuited on the high-voltage side

at the transformer panel of the MV switchgear.
11. Remove FO cable connection and shut down NFC.
12. Dismantle the slip ring cable of the Centerbox
3.2.1 Required securements switched on
The following securements of the WT must remain switched on. Before start of the
connection, compare the device identifications with the current circuit diagram of the WT.
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Topbox
TOB1
24 VDC general supply =APSELESUP+TOB1-FC1
24 VDC bus terminals, switches supply fuse =APSELESUP+TOB1-FC2
24 VDC yaw supply =APSELESUP+TOB1-FC7
Supply PLC-Input/Output =APSELESUP+TOP1-FC5
TOB2
Sockets RCD =APSELESUP+TOB2-FB1
Bottombox lighting supply =APSELESUP+TOB2-FC15
230 VAC UPS supply =APSELESUP+TOB2-FC19
Start delay supply =APSELESUP+TOB2-FC20
230 VAC UPS control/yaw system supply =APSELESUP+TOB2-FC21
Nacelle/Hub lighting supply =APSELESUP+TOB2-FC25
Supply 230 VAC UPS Switch =APSELESUP+TOB2-SF3
grid contactor control =APSELESUP+TOB2-FC14
Heat up Topbox cold weather conditions =CLCCLIMAT +TOB2-FC2
TOB3
Bottombox supply =APSELESUP+TOB3-FC30
Topbox supply =APSELESUP+TOB3-FC31
Service crane-/socket outlets supply =APSELESUP+TOB3-FC33
Hub erection supply 3 =APSELESUP+TOB3-FC34
Yaw supply =APSELESUP+TOB3-FC13
Bottombox
External Power Supply Max 30KVA =APSELESUP-FC1
Switch-disconnector External Power Supply =APSELESUP-QB2
Input Auxiliary Power =APSELESUP-FC2
Switch on Mains Auxiliary Operation =APSELESUP-FC0
Supply E-Boxen Tower 400V AC/ Lift Fuse =APSELESUP-FC3
Supply E-Boxen Tower 400V AC/ Lift RSD =APSELESUP-QA3-FC5
24 VDC UPS Temperature Starting Circuit =APSELESUP-FC10
Lightning Cabinet =APSELESUP-FC4

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3.2.2 Disconnecting transformer
Ground Electrically skilled person
DANGER
Electric voltage!
Potentially fatal injuries when working on parts of the electrical system.
 Disconnect electrically conductive parts in compliance with the

5 safety regulations.
 Make sure that only electrically skilled persons perform the work.
1. Disconnect the WT at the upstream system/point of common coupling (substation)

and establish grounding.
2. Make sure that remote operation of the controls is not possible.
3. Make sure that the owner has permanently deactivated the WT.
3.2.3 Disconnecting cable connection MV switchgear
Tower base Electrically skilled person
DANGER
Electric voltage!

1. Disconnect grounding cables W1010 and W1037 between tower shell and
MV switchgear.
2. Disconnect the ring cable on the MV switchgear.
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DANGER
Electric voltage!

1. Disconnect grounding cables W1010 and W1037 between tower shell and MV
switchgear.
3.2.5 Establishing the portable power supply
Ground, tower, nacelle Electrically skilled person
DANGER
Electric voltage!

5 safety rules:
 Disconnect completely
 Secure against reconnection
 Verify that the installation is dead
 Ground and short-circuit
 Provide protection against adjacent live part

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The work may only be carried out by correspondingly trained personnel.
For the power supply of the WT a power unit with an output of at least 40 kVA at 400 V
is required.
The power supply unit is connected to the Bottombox with an adapter cable. The Bottombox
has a 63 A CEE plug underneath t he tower access level.
The adapter cable is routed through an opening below the tower door.
1. Make sure that the following steps were completed:
 The MV switchgear is disconnected.
 It is verified that the system is dead.
 The MV transformer is grounded and short-circuited on the high-voltage side at the
 transformer panel of the MV switchgear.
 The MV switchgear is protected against reactivation in accordance wit the

LOTO documented procedure.
 The WT is dead.
3.2.6 Assembling and positioning transport frames
3.2.6.2 Transport frame – rotor hub
Ground Technician
Operating instructions E0004887746 Transport device for the rotor hub
1. Set up the rotor hub transport frame on a level and stable support.
2. Make sure that the transport frame is at a minimum distance X= 800 mm from the
ground. 200 mm distance is needed for the spinner, and 600 mm is needed as
workspace for the service technicians.
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Fig. 2: Minimum distance transport frame to ground

(figures show rotor hub without spinners)
3.2.6.3 Assembling and positioning transport frames

If the rotor blade touches down on uneven ground, it may get damaged. This applies
in particular in the area near the rotor blade root. Avoid any contact of the rotor blade
with the ground.
 Assemble and position tip and transport frame on a horizontal and stable support.
3.2.7 Setting the pitch tower damping
Rotor hub, rotor blade Technician
The pitch absorption prevents outward vibration of the WT. To this end a rotor blade is
pitched to 11°. The other two remain in the feathered position. The wind turbine is
then unlocked and idles.
1. Make sure that the rotor lock has been inserted.
2. Pitch an upper rotor blade preferably in 11º position.
3. Make sure that the rotor blade in 11° position is not in the gray area of the
following figure.
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Fig. 3: Setting the pitch tower damping
4. If it is not possible to set the pitch tower damping, then make sure that the frictional
guy rope is active.
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3.3 Bringing devices, tools and materials to the nacelle
Ground, tower, nacelle Electrically skilled person
 Bring all necessary devices, tools and materials into the nacelle.
3.4 Removing the coupling contact protection
Nacelle Technician
 The rotor lock is engaged.
 Drivetrain Permit to Work must be available.
CAUTION
Cutting injuries!
Sharp cover edges may lead to cut injuries.
 Wear safety gloves.

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Fig. 4: Removing the coupling contact protection
1 Guard in pre-assembled 2 Frame 9

condition
3 Cover 5 4 Frame 6
5 Cover 2 6 Frame 3
7 Cover 6 (bottom) 8 Brake cover
9 Cover 6 (top) 10 Frame 5
11 Right cover 12 Left cover
13 Hex screw 14 Washer
5. Open the two locking clamps and remove the cover on the left (12).
6. Remove the right cover.
7. Remove the brake cover (8) on the right side of the frame.
8. Remove cover plate 2 (5).
10. Remove cover 6 top (9).
11. Remove cover 6 bottom (7).
12. Remove frame 6 (4) between frame 9 (2) and frame 5 (10).
13. Remove frame 5 (10).
 After disassembly, the parts must be stored safely in the NAC.

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3.5 Disassembling the slip ring unit
3.5.1 Removing the slip ring cable
Nacelle, rotor hub Electrically skilled person
 Drivetrain Permit to Work must be available
CAUTION
Hazardous voltage!
Electric shock from incorrect handling of the electrical equipment.
 Before carrying out work on parts of the electrical system, they must be
disconnected in compliance with the 5 safety rules.
 An electrically skilled person performs electrical uninstallations.
 Verify that the system is dead.
3.5.2 Disassembling the slip ring unit
Nacelle Electrically skilled person
 Rotor lock is set.
DANGER
Entanglement hazard!
Entanglement hazard at the gearbox output shaft.
 Lock the rotor before working on the slip ring.
DANGER
Hazardous voltage!
Parts of the electrical system of the WT may carry hazardous voltage.

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Any contact with live parts may result in death or serious injury
 All tasks must be carried out only by trained electrically skilled persons.
 Disconnect main converter (AIS) and Topbox prior to assembling the slip
ring unit.
The slip ring cable needs to be carefully secured on the drive train after being
disassembled.
Fig. 5: Slip ring with coupling
A. Slip ring coupling 1 Assembly flange

B. Slip ring 2 Protective cap
3 Torque arm
1. Disconnect electrical connection on the slip ring.
2. Remove the torque arm.
3. Disconnect slip ring unit from the plug-in coupling half on the gearbox side.
4. Put on protective caps on FO cable contact.

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3.6 Disassembling the generator coupling
Nacelle, ground Electrically skilled person, technician
BOM component Screw size Tightening torque
Hex screw ISO 4017 M10x35-8.8-tZn M10 -
Hex screw ISO 4017 M16x90-8.8-tZn M16 -
Hex screw ISO 4017-M24x70-10.9-flZnnc M24 850 Nm
Cylinder head screw DIN 912-M16x60-12.9 M16 250 Nm
Cylinder head screw DIN 912-M20x90-12.9 M20 490 Nm
Cylinder head screw M27x120-10.9 M27 1070 Nm
Hex screw ISO 4014-M24x110-10.9 M24 840 Nm
Tool
Mechanical torque wrench - -
 The electrical connections on the drive train are disconnected.
 Use the overhead crane to remove the generator coupling.
 Only disassemble the intermediate shaft. Do not disassemble the brake disk at
the gearbox and clamping set at the generator.
 Loosen the screws in a crosswise sequence.
 After disassembly, dispose of screws
WARNING
Risk of injury from falling loads!
The load attached to a crane hook can swing, tip over or fall. This can result in
serious injury.
 Always observe a safety distance from the attached load.

Risk of serious injury from screw connections shooting off explosively
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The screw connections of the intermediate shaft can shoot off explosively due to
high stored energy (pressure or spring energy). This may cause serious head,
hand or arm injury from impact or crushing.
 Maintain an adequate safety distance.

 Protect these parts of the body.
 Loosen the screws in a criss-cross pattern; do not unscrew them completely.
Risk of serious injury from the intermediate shaft falling down
If an unsecured intermediate shaft comes loose, it can fall down uncontrollably.

This can result in serious injury.
 Secure the intermediate shaft against falling down using the overhead crane
and lifting tackle.
There are 2 types of generator couplings:
 Link coupling (CENTA coupling)
 Multi-disk coupling (KTR and FLENDER coupling)
Fig. 6: Slip ring with coupling
A. Link coupling (CENTA coupling) 2 Intermediate shaft

B. Multi-disk coupling (KTR coupling) 3 Brake disk at the gear
1 Clamping set generator side
1. Before disassembly, secure the intermediate shaft against falling.
 Position the overhead crane above the center of gravity of the intermediate shaft.
 Place a round sling (WLL 1 t, EWL 2 m) around the intermediate shaft and secure it
to the hook of the overhead crane.
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2. Remove the intermediate shaft.
3. Store the disassembled components securely in the nacelle.
3.7 Installing the turning drive in the nacelle
Operating instructions E0002893094 Operating instructions for the turning drive
CAUTION
Overloaded overhead crane!
Material damage.
 Always observe the maximum load capacity of the overhead crane when
transporting the turning drive.
 Use the main crane.
 Transport and assembly of the turning drive according to document E0002893094

 Assemble the turning drive onto the generator frame, see document E0002893094.
3.8 Disconnecting the MV cables
Tower, nacelle Electrically skilled person, technician
 The coupling guard has been removed.
 The generator coupling has been removed.
 The slip ring has been removed.
The MV cable will be cut through and secured.
The MV cable is cut at the level of the top flange and the intermediate flange between the top
section and the mid-section and secured in the tower.
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3.8.1 Disconnecting MV cable from MV switchgear
CAUTION
Hazardous voltage!
Note on qualifications
 This work may only be carried out by an electrically skilled person with proven
qualifications for the installation of MV cables.
1. Make sure that the following preliminary tasks have been completed:
 Circuit-breaker panel is shut off and grounded.
 Bracket is released from current transformers.
2. Disconnect protective cap from plug housing.
3. Disassemble screw closure insert.
4. Disassemble the upper parts of the cable clamps in the cable connection.
Fig. 7: Current transformer in the switchgear
5. Pull MV cable through current transformers downward.

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3.8.2 Disconnecting MV cable from transformer
CAUTION
Hazardous voltage!
Note on qualifications
 This work may only be carried out by an electrically skilled person with proven
qualifications for the installation of MV cables.
1. Disassemble the covers over the connections.
2. Disassemble the copper rail for grounding the surge arresters.
3. Remove protective cap from surge arrester.
4. Disassemble screw closure insert.
5. Loosen MV cable from the 3 cable clamps in the housing.

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Fig. 8: MV cables on the transformer
1 Vertical rod 3 right 2 Cable clamps

3 Main grounding bar
6. Disconnect MV cable from post 3 right.
7. Disconnect the grounding cable from the MV cable of the main grounding bar.
3.8.3 Securing MV and supply cables
1. Secure the MV cable to the second cable harness (cable harness which is free) with a
winch or chain hoist to the PAP opposite the ladder on the oil-proof platform
(cable weight loop approx. 280 kg at 35 m length). The winch or chain hoist remains
above the oil-proof platform and the rope is fed through the opening for the MV cable.
2. Lift the cable slightly by means of a cable winch or chain hoist.

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Fig. 9: View of underside of oil-proof platform
1 PAP for fastening the winch or chain hoist
3. Secure the supply cable below the intended cut surface with at least 10 cable ties on
the MV cable.
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3.8.4 Disconnecting the MV and supply cables
1. Disconnect MV and supply cables below the nacelle.
Fig. 10: Disconnect the MV and supply cable below the nacelle
1 Position where the cables are

disconnected
2. Disconnect MV and supply cables on the topmost flange platform
 Loosen the cable sleeve of the MV cable
 Disconnect the MV and supply cables

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Fig. 11: Disconnect the MV and supply cable below the nacelle
1 Position where the cables are

2 1st cable clamp
disconnected
3 Cable-support grip 4 MV cable
5 Position where the MS cable is 6 Position where the supply
disconnected cables are disconnected
3.9 Removing the MV switchgear
Hex screw ISO 4017-M12x25-10.9-tZn M12
Hex screw ISO 4017-M10x70-8.8-tZn M10 Hand-tight
Button head screw ISO 7380-2-M8x20-010.9-galZn M8
Button head screw ISO 7380-2-M8x30-010.9-galZn M8
Hex screw ISO 4017-M12x45-8.8 M12
Hex nut NALL12_066159-M10-8-tZn M10
Hex screw ISO 4017-M16x45-8.8-tZn4 M16 153 Nm
Hex screw ISO 4017-M12x100-8.8-tZn M12 63 Nm
Hex screw ISO 4017-M12x45-8.8-tZn M12 63 Nm
The MV switchgear is located in the tower base on the access platform of the WT.
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3.9.1 Assembling substructure and electrical winch
Nacelle Metal worker
Operating instructions 2009798IN Mobile working platform TOPlift L
The substructure for the electric cable winch consists of 4 components which are assembled in
the nacelle.
DANGER
Fall hazard from unsecured working
Falls may result in death or serious injury.
 When removing the tread plate cover or mounting the winch, secure with
PFPE at the personnel attachment points.
1. Disassemble tread plate 2 and tread plate 4 on the right side of the machine frame.
2. Disassemble the tread plate cover in the gearbox input shaft transition.
3. Assemble pre-assembled substructure for electrical winch on the machine frame.
Fig. 12: Assembly site for substructure electrical winch
4. Install electrical winch into the substructure.

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Fig. 13: Electrical winch on the substructure
1 Electric cable winch 2 Substructure
DANGER
Electric voltage
 Disconnect electrically conductive parts in compliance with the 5 safety

regulations.
1. Disconnect grounding cables W1010 and W1037 between tower shell and
MV switchgear.

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3.9.3 Disconnecting control and signal cables
DANGER
Electric voltage

regulations.
 Disconnect control and signal cables.

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3.10 Switching off pitch battery voltage
DANGER
High electrical voltage, even when the circuit is interrupted
Do not touch electrically conductive battery parts. This may lead to fatal injury.
 Make sure that a second person is present during all electrical work.
 Switch off the battery voltage on all 3 battery boxes on the battery disconnector.
3.11 Setting the pitch gearbox lock
DANGER
1 x special tool pitch drive is located in the yaw area of the nacelle.
A total of 3 x special tool pitch drive must be available at the construction site.
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Fig. 14: Pitch gearbox lock
1. Remove the cap for the lock hole.
2. Fully screw in the pitch lock with the special tool on all 3 pitch drives.
 All 3 pitch gearboxes locked.
3.12 Removing the pitch gearbox lock
DANGER
Remove pitch gearbox lock only on the rotor blade that is to be removed; the other
2 rotor blades remain locked.
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Fig. 15: Pitch gearbox lock
 Remove pitch gearbox lock on the rotor blade that is removed.

 Remove the special tool on the pitch gearbox.
3.13 Decommissioning the limit switch
 All 3 rotor blades are positioned in the stop position.
 All 3 pitch drives are locked.
DANGER
Green LED must be on and unloading switch must be fixed, otherwise
uncontrolled rotation of the rotor blade may occur.
If the limit switch rotates during disassembly, pitch movements may occur.
1. Secure the end-bearing switch with a cable tie.

2. Insert the erection jumpers in the pitch box. The signals of the limit switches are
bridged using a jumper for the stop position to be permanently activated.
3. Pull the limit switch out of the gearing, attach it and secure it with cable ties
against twisting.
 The green LED at the device is lit.

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Fig. 16: LED on the limit switch
3.14 Connecting supply voltage
1. Insert the erection jumpers in the pitch box. The signals of the limit switches are
bridged using a jumper for the stop position to be permanently activated.
2. Set the service switch Service Mode on the Centerbox into position 2.
 External power supply is established.
Fig. 17: Switch at the Centerbox
1 Service switch 2 Selector switch

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3.15 Activating service mode
Fig. 18: Switch at the Centerbox
1 Service switch 2 Selector switch
 Set corresponding axis with service switch +CEB=APSELESUP-SF1 to position 0.

 Pitch drive of the corresponding axis is now selected for manual operation.
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3.16 Removing the rotor lock disk cover
Nacelle Technician
3.16.1 Removing the cover plates
Fig. 19: Rotor lock disk guard cover plates (view towards rotor hub)
1 Cover plate 3 2 Cover plate 1

3 Inspection window 1 4 Cover plate 2
11 Cover plate 11 12 Inspection window 2
15 Cover plate 4
1. Remove cover plate 10 (10) from the rotor bearing housing.

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3. Remove cover plate 8 (7) from the rotor bearing housing.
4. Remove cover plate 13 (8) from frame section 2 and cover plate 9.
5. Remove cover plate 9 (9) from frame section 2.
6. Remove cover plate 7 (6) from frame section 1 and frame section 5 on the right.
7. Remove cover plate 5 (5) from frame section 1 and frame section 5 on the right.
8. Remove cover plate 2 (4) from frame section 2, frame section 3 and frame section 1 on
the right.
9. Remove inspection window 1 (3) from cover plate 1.
10. Remove cover plate 1 (2) from frame section 2 on the left and right, frame section 3
and frame section 4.
11. Remove cover plate 3 (1) from frame section 2 and frame section 1 on the left.
14. Remove inspection window 2 (12) from frame section 1, frame section 2 and bracket 3.
15. Remove cover plate 12 (13) from bracket 3 and frame section 1 on the left.
 Safely store in the nacelle.

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3.16.2 Disassembling the frame
Fig. 20: Rotor lock disk guard frame (view towards rotor hub)
1 Frame section 2 2 Frame section 4

3 Bracket 1 4 Frame section 3
7 Frame section 5 8 Bracket 4
9 Bracket 2 10 Spacer sleeve
13 Bracket 6
1. Remove 5 x spacer sleeve (10).
2. Remove 2 x holder 3 (11) from rotor bearing housing.
3. Remove holder 6 (13) from frame section 1 (6) and roof rack.
4. Remove holder 5 (5) from frame section 1 (6) and roof rack.
5. Remove 2x holders 1 (3) from frame section 4 (3), on the right of frame section 3 (4)
and on the right and left of the roof rack.
6. Remove frame section 3 (4) on the right of frame section 2 (1).
8. Remove 2 x frame section 2 (1) on the left and right of frame section 1 (6).
10. Remove frame section 6 (12) on the right side of frame section 1 (6).
11. Remove 2 x frame section 1 (6) on the left and right of bracket 4 (8).
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12. Remove 2 x brackets 4 (8) on the left and right of bracket 2 (9).
13. Remove 2 x brackets 2 (9) of the machine frame.
 Safely store in the nacelle
3.17 Disassembling cable and cable guide rotor blade
Rotor hub, rotor blade Technician, electrically skilled person
Repeat the following steps in this chapter in sequence for all 3 rotor blades.
1. Remove cable at bottom of blade.
2. Loosen cable guide from bottom of rotor blade.
3. Roll up cable guide and cable in the director of the pitch console and secure
for transport.
4. Remove loose materials from the blade root compartment.
Fig. 21: Rotor blade cable tray

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4 Rotor blades
CAUTION
The center of gravity of the blade must be taken from the weighing and balancing
protocol of the wing manufacturer or from the transport protocol, since this can
deviate from the marked center of gravity on the blade itself! As a counter-check,
carry out a center of gravity measurement, see Section 4.2.1.
The rotor blades and dismantled one after another working at heights.
4.1 Preparing the rotor blade assembly
4.1.1 Safety measures required if rotor blade disassembly is interrupted
Nacelle, ground Technician
Srv reduced shank bolt M36 Preload torque: 800 Nm

FAT M36x445/105/88-10.9-tZn
Collar nut M36-10-tZn M36 -
Pan head screw ISO 7380-M10x16-A4-70 M10 -
Tool
Special tool for pitch drive - -
Impact wrench - -
Tensioning cylinder M36
If rotor blade disassembly work is interrupted, move the remaining rotor blades into a
safe position.
DANGER
Fall hazard
 Close the entries to the blade root compartment each time before rotating
the hub.
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1. Rotate the rotor hub using the turning drive.
 The rotor blades to be removed point down.
2. With a single rotor blade remaining: Engage the rotor lock.
Property damage due to standstill markings in the rotor bearing
 Do not engage the rotor brake for more than 24 hours.

 For interruptions of more than 24 hours: Rotate the rotor once by 360° using
the turning drive.
3. Apply rotor brake for 2 remaining rotor blades.
4. If the wind speed is higher than 12 m/s: Remove the turning drive.
4.1.2 Aligning the nacelle to the crane
Nacelle Technician
 For rotor blade disassembly, align the nacelle with the crane.
4.1.3 NR 74.5 Preparing rotor blade bolts
Nacelle Technician
DANGER
Fall hazard
the hub.
1. Release the rotor lock and open the rotor brake.
2. Rotate the rotor with the turning drive until the disassembled rotor blade points down
(Y position).
3. Apply the rotor brake and lock the rotor.
4. Lock the pitch gearboxes.
5. Mark 50 rotor blade bolts in the designated areas.

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Fig. 22: NR74.5: Rotor blade bolt
6. Next loosen all 112 rotor blade bolts with the tightening cylinder one after another and
then tighten them each immediately with an impact wrench.
 Tightening torque: 800 Nm
7. Activate the pitch damping
8. Perform steps with all three blades
4.1.4 Bringing the rotor blade into a horizontal position
Nacelle Technician
DANGER
Fall hazard
the hub.
2. Rotate the rotor blade to be removed between the 6 o’clock and 4 o’clock positions.
3. Attach the guide rope to the blade tip outside the serrations (approx. 25 m from the
blade tip).
4. Rotate the rotor blade to be disassembled to the 6 o’clock position.
5. Remove the nuts of all unmarked rotor blade bolts.
 Now the rotor blade is only assembled with the marked rotor blade bolts.
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6. Rotate the rotor with the turning drive until the rotor blade to be disassembled is in the
horizontal disassembly position (3 o’clock position or 9 o’clock position).
7. Apply the rotor brake and lock the rotor.
4.1.5 Attaching the guide ropes to the rotor blade
Nacelle Technician
A prerequisite for operating a lifting cage must be available:
 Note to the BG (NX or crane operator)
 The crane itself must be approved for the transportation of persons
 Lifting cage must be checked
 Lifting cage must be padded
NOTE
The following steps are only required when attaching the rotor blade with the rotor
blade lifter.
NOTE
The rope must not be attached to the lifting cage, but to the crane.
1. Lock the pitch gearboxes.
2. Attach the guide rope (min 250 m) to the rotor blade tip:
 Place with the lifting cage incl. protection at the handling area with double rope loop
around rotor blade tip.
 Padded end edge protection (with fastening eyelet to secure against falling down)
already installed in the loop.
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Rev.: 00
Fig. 23: Edge protection without padding
 Pull up and fasten with a telescopic rod incl. hook Loop
3. Attach the guide rope to the rotor blade root:
 With the lifting cage, place a tape sling (10m) around the rotor blade root in front of
the rain deflector (from the direction of view of the rotor blade tip). Use a telescopic
rod incl. hook and keep 200 mm distance from the rain deflector.
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4.2 Removing the rotor blades
4.2.1 Attaching the rotor blade to the crane
Nacelle Technician
Attaching rotor blade with Certex rotor blade lifter
 If not yet present, mount the shield/reflector on the crossbeam
C enter of mass
C ertex rotor blade lifter
Fig. 24: Center of mass and Certex rotor blade crossbeam
1. Turn blade to horizontal position (6 or 9 o’clock position)
2. Pitch the blade so that the blade fin is in the horizontal position (0° position)
3. Lock the pitch gearbox. Attach the rotor blade to the center of gravity of the rotor blade
using the rotor blade lifter (observe the balancing protocol).
4. Manually check the distance x between the blade root and the crossbeam using a laser
range finder (see figure). The center of gravity of the rotor blade must be x + t/2 away
from the blade root
5. Raise the rotor blade with the rotor blade lifter until the blade weight is reached, while
controlling the traverse from several positions
6. Tighten the guide ropes.
7. Control routes.
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4.2.2 NR74.5 Removing screw connections
Nacelle Technician
BOM component Quantity Spec.
Round sling 1 -
Chain hoist 1 -
1. Make sure that the crane has absorbed the entire blade weight.
2. If there are any, remove the grounding straps between extender and rotor blade.
3. Loosen and remove marked rotor blade screw connections.
Fig. 25: NR74.5: Rotor blade bolt
4. Pull the round sling through both grommets using an edge protector and tension the
chain to the hub body to ensure controlled release of the blade.
5. Rotate 4 x nuts on the end of the rotor blade bolt 90° each until flush on a readily
accessible rotor blade screw connection. Note: This prevents the rotor blade from
vibrating outwards.
6. Carefully raise or lower the rotor blade if necessary.
 The rotor blade bolts move freely inside the drill holes.
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WARNING
Suspended rotor blades may start swinging abruptly
Risk of fatal crushing injury.
 Maintain a safe distance.
WARNING
When turning the rotor, check the paths of travel of the other blades.
7. Remove the rotor blade from the rotor hub with the cranes.
8. Lower the blade
9. Mount blade root on the root cradle
10. Tilt the crossbeam so that the blade tip is tilted downwards
11. Place blade in end position
12. Remove all loose tools and parts from the rotor hub
13. Disengage the rotor lock
14. Turn the next blade to 6 or 9 o’clock position and repeat steps
4.2.3 Lowering the rotor blade
Nacelle, rotor hub Technician
WARNING
Suspended rotor blades may start swinging abruptly
Risk of fatal crushing injury.
1. Slew the rotor blade away from the rotor hub.
2. Lower rotor blade and deposit in the storage area.

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4.2.4 Disengaging the rotor lock

Nacelle Technician
WARNING
Turning the rotating device in the wrong direction may damage the rotor
lock disk.
1. Move the rotary motor against the load of the blades to reduce the load on the
rotor lock.
2. Disengage the rotor lock.

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Rev.: 00
5 Rotor hub
5.1 Marking screw connections for disassembly position
Srv stud bolt M27x248/80-10.9-tZn M27 Preload torque: 400 Nm
Srv collar nut M27-10-tZn M27 -
Hex nut ISO 7040-M8-A2-70 M8
Hex nut ISO 4032-M36-10-tZn M36 approx. 80 Nm
Tool
Impact wrench - -
Hydraulic tool with tightening cylinder
Hydraulic torque wrench
WARNING
Rotor lock disks slipping off
When disassembling the rotor hub, an unsecured rotor lock disk can slip off.
This can result in life-threatening injuries.
 Secure rotor lock disk.
1. Ensure that the rotor lock disk is secured inside the hub connection bolt circle with
3 x alignment pins M36 and 3 x hex screws M36.
3. Rotate the rotor hub using the turning drive until the pointer at the rotor bearing
housing points to marking 1 on the rotor lock disk.
4. Apply rotor brake and secure rotor hub with rotor lock.
 Service hatch is located above.
 Rotor hub is positioned in the (later) disassembly position.

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5. Mark the following screw connections. (Minimum number, 49 x in total)
Fig. 26: Accessible screw connections on the rotor flange
1 Screw connections at the left

2 Screw connections above at
and right (inner and outer ring
the center (inner ring 1 x)
15 x each)
9 x each)
5.2 Disassembling unmarked screw connections
In the following steps the unmarked screws at the rotor flange are removed. The rotor hub is
rotated for this purpose.
2. Rotate rotor hub with turning drive so that the unmarked screws can be reached.
3. Engage the rotor brake.
4. Apply the rotor lock.
5. Release and remove accessible unmarked screws.

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6. Loosen screw connections with tightening cylinder and remove nuts.
7. Disengage the rotor lock.
8. Release the rotor brake.
9. Rotate the rotor with the turning drive until more unmarked screw connections
are accessible.
10. Engage the rotor brake.
11. Apply the rotor lock.
12. Repeat steps 1 to 8 until all unmarked screws have been released and removed.
14. Rotate the rotor hub using the turning drive until the pointer at the rotor bearing
housing points to marking 1.
15. Apply the rotor brake and engage the rotor lock.
 Service hatch is located above.
 Rotor hub is positioned in the disassembly position.
 All marked screw connection are accessible.
16. Mount guide rope
 Rope is attached to the crane hook so that 20m are suspended freely
 Lifting case and rope lifted and guide rope is attached to the hub by means
of a swivel block (M36)
5.3 Removing the service hatch
Rotor hub Technician
The service hatch is a single piece.
 Disassemble the service hatch in the spinner segment.

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Fig. 27: Removing the service hatch
5.4 Securing the service hatch
DANGER
Risk of falling objects
An insufficiently secured service hatch may fall when disassembling or lowering the
rotor hub.
 Secure the removed service hatch.
The removed service hatch is lowered together with the rotor hub.
 Secure the removed service hatch.

o Mount tensioning ropes on the grab handles and secure them to the hub frame
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5.5 Assembling the LLA rotor hub
 The service hatch is removed.
Operating instructions E0004875246 Load lifting attachment
The screws are included in the scope of supply of the rotor hub LLA.
DANGER
 Always secure yourself at the personal attachment points with the PFPE while
working in fall hazard areas.
1. Assemble LLA rotor hub between axis 2 and axis 3 with M36 hex screws on the
rotor hub.
1 Shackle 75 t 2 Suspension lug

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5.6 Attaching the rotor hub and lifting the load
1. Connect LLA rotor hub to the main crane.
2. Slowly take up the load on the hook of the main crane until the total load of the rotor
hub is reached.
 The load capacity depends on the weight of the rotor hub, see chapter 14.1 “Tools”
and weighing protocols (approx. 64 t).
 If available, take the weight of the rotor hub from the erection report.
3. Tighten the guide ropes.
5.7 Disassembling marked screw connections
 LLA is attached to the rotor hub in accordance with specifications.
 The total weight of the rotor hub is absorbed as load by the main crane.
 The wind speed is within the crane driver specifications.
DANGER
Risk of life-threatening injuries
If the rotor hub is not attached correctly, it may come lose and fall into the webbing
slings.
 Complete all disassembly instructions in the correct order.

 Only use tested and approved LLA.
 Pay close attention to the load lifting information on the main crane and
check the load before removing the rotor hub.
1. Select removal position so that the hub can be swung away to the side, unless a
crawler crane is used
2. Loosen previously marked M27 stud bolts between rotor hub and rotor shaft with
clamping cylinder one after the other and tighten each immediately with an
impact wrench.
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2 Screw connections above at
the center (inner ring 1 x)
15 x each)
9 x each)
3. Fully loosen all screw connections with the impact wrench and remove the screws.
 All screw connections of the rotor hub on the rotor flange are released
and removed.
 Install the fourth mounting mandrel (3x)
4. Rotate 1 x nut on the end of the bolt until flush on a readily accessible screw
connection. Note: This prevents the rotor hub from vibrating outwards.
5. Slew rotor hub carefully away from drive train using the crane until both nuts are in
contact again.
6. Make sure that the bolts are free-standing in the drill holes when the rotor hub from the
groove is below.
7. Stop crane and disassemble nuts.
8. Slew rotor hub away. If a longer guide of the rotor hub is needed, then a guide pin can
also be used as support.
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 Rotor hub hangs loosely.
5.8 Lowering, rotating and setting down the rotor hub
When lowering heavy loads, the crane may make noise due to the winch. This is to be
mentioned in the separate toolbox talk.
Operating instructions E0004795547 Device for rotating and storing
WARNING
Risk of tilting and subsiding
The LLA/rotor hub rack may tilt or subside on sloping or soft ground.
 Always store the LLA/rotor hub rack on a stable support.
1. Carefully lower and install rotor hub on the rotation and storage rack.
2. Remove all 27 stud bolts from the rotor hub.
3. Attach rotation and storage rack to t he auxiliary crane.
Fig. 30: Rotor hub on the rack

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4. Lift the rotor hub simultaneously with the main crane and the auxiliary crane.
 The auxiliary crane picks up the load.
 The main crane follows.
 The rotor hub is turned by 90°.
5. Lift up the load with the auxiliary crane until the rotor shaft flange is suspended
horizontally.
Fig. 31: Rotor hub on transport frame
6. Lower and install rotor hub on transport frame.
5.9 Disassembling the LLA rotor hub
Operating instructions E0004875246 Load lifting attachment
DANGER
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1. Remove the guide ropes.
2. Disassemble LLA rotor hub between axis 2 and axis 3.
3. Seal threaded holes in rotor hub base body with Unipass pipe plugs.
5.10 Removing rotation and storage rack
 Rotor hub is positioned on the transport frame
 The main crane has not picked up the load.
 Storage rack is fastened to the auxiliary crane.
1. Remove spinner of the rotor hub.
2. Remove the rack.
3. Lower storage rack with auxiliary crane.
5.11 Disassembling the spinner
5.11.1 Removing the spinner from the rotor hub

Ground Technician
Eyebolts M16 M16 60 Nm
Hex screw ISO 4017-M10x30-A2 M10 10 Nm
Tool
Mechanical torque wrench - -

Doc.: 2030290EN
Rev.: 00
DANGER
Fall hazard
Fall hazard if the safety instructions are not observed.
 Use suitable equipment for work on the hub, e.g. ladder, cherry picker
or scaffolding.
 Use suitable resources only on a level and stable support.
 Secure yourself at the personal attachment points with the PFPE.
Spinner can be disassembled using a telescopic forklift or a crane. When disassembling

with a telescopic forklift, always use forklift hooks. 2 forklift hooks are included in the
installation container. Place disassembled components directly on the transport frame.
Fig. 32: Segments of the spinner
1 Segment 2 2 Segment 1
3 Segment 3
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5.11.2 Removing the rescue hatch
Fig. 33: Rescue hatch
1 Rescue hatch 2 Clamping nut with washer

3 Seal
 Loosen the clamping nut and remove the escape hatch (1).
5.11.3 Opening the mounting holes on the rotor hub
Fig. 34: Position of the mounting holes on the rotor hub
Fig. 35: Fixing plate of mounting hole
 Remove 6 x hex screws (1) and washer (2) from the mounting plate (3).
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5.11.4 Removing spinner segments 2 and 3
Fig. 36: Segment 2 and 3
1 Segment 2 (3 x) 2 Segment 1 (3 x)
3 Segment 3 (3 x)
1. Remove segment 3
 Remove 3 x segment 3 (3) from segments 1 (2)
 Tightening torque: 29.5 Nm
2. Remove segment 2
 Remove 3 x segment 2 (1) from segments 1 (2)
 Tightening torque: 29.5 Nm
5.11.5 Attaching spinner segment 2 to the crane
Fig. 37: Segment 2 attachment point
1 Attachment point for M10

eyebolt
1. Mount M10 eyebolt in segment 2.
2. Attach segment 2 to the eyebolts.

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5.11.6 Removing supporting structure
Fig. 38: Support structure
 Remove 3 x SKA bracket from the TSC bracket and spinner segment 1.
5.11.7 Removing spinner segment 1 from supporting structure
Fig. 39: Segment 1 to bracket TSC
1. Remove 3 x segment 1 with 4 x hex screws and 4 x washers from bracket SDA.
2. Remove 3 x segment 1 from TSC bracket with 4 x hex screw and washer.
3. Unthread 3 x segment 1 from the hole in the TSC bracket.

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5.11.8 Attaching spinner segment 1 to the crane
Fig. 40: Spinner segment 1 attachment points
1. Screw 2 x M16 eyebolts into the mounting plates of spinner segment 1.
2. Attach spinner segment 1 to the eyebolts and raise.
5.11.9 Removing the support structure from the rotor hub
Fig. 41: Support structure at rotor hub
1 TSC bracket 2 Hex screw ISO 4017-M16x90-8.8-tZn

3 Washer ISO 7089-16-300HV-tZn 4 Extension sleeve 32/18x45
5 Washer DIN 6340 17-350HV-tZn
 Dismantle 3 x TSC brackets (1) from the rotor hub.

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5.12 Preparing turning drive for disassembly
The turning drive is not disassembled; it is lowered down together with the drive train.
 Disassemble all cables and hoses between turning drive and hydraulic unit.
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6 Drive train
6.1 Preparing disassembly of the drive train
 Rotor blades and rotor hub are disassembled.
 The generator coupling has been removed.
6.1.1 Disconnecting the electrical connections of the drive train
DANGER
Electric voltage
Any contact with live parts may result in death or serious injury.

regulations.
1. Disassemble PT100 beneath rotor bearing housing.
2. Disconnect speed sensor of the input shaft.
3. Disconnect cable connections on box 5 and box 7.
4. Disconnect cables of the CMS sensors from the CMS box.
5. Disconnect grounding cables on the left and the right from the gearbox.
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6.1.2 Disassembling ALU rotor bearing lines
Drive train Technician
 The service hatch is removed.
The three lubricant lines on the drive train and in the nacelle are routed to the right
post 1.
1. Assemble LLA rotor hub between axis 2 and axis 3 with M36 hex screws on the
rotor hub.
Fig. 42: Disconnect ALU rotor bearing lines
2. Remove lubrication supply hoses.
6.1.3 Disassembling the water cooler of the plate-type heat exchanger
DANGER
Lines and structural components are under high pressure
Risk of serious injury due to sudden movement of structural components and lines if
the hydraulic system is not completely depressurized.
 Release the pressure from the hydraulic systems. Then make sure that no
pressure exists.
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The plate-type heat exchanger for gear oil cooling is located on the right -hand
gearbox side.
1. Close 4 x ball valves below the access level.
2. Disconnect the cooling circuit between both ball valves.
3. Secure the two hydraulic hoses remaining at the drive train with cable ties.
6.1.4 Disconnecting the hydraulic system
Nacelle Technician
DANGER
Lines and structural components are under high pressure
Risk of serious injury due to sudden movement of structural components and lines if
the hydraulic system is not completely depressurized.
 Release the pressure from the hydraulic systems. Then make sure that no
pressure exists.
The pressure hose for the rotor brake that connects the pipe on the generator frame
and the pipe on the drive train must be disconnected. If a KTR rotor brake is installed,
then this is not necessary.
1. Close 4 x ball valves below the access level.
2. Disconnect the cooling circuit between both ball valves.
3. Secure the two hydraulic hoses remaining at the drive train with cable ties.
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Fig. 43: Hydraulic unit block HYDAC
1 Shut-off valve 4 2 Pressure gauge
Fig. 44: HAWE hydraulic unit
1 Shut-off valve 100.a/100.b 2 Pressure gauge
1. Open shut-off valves on hydraulic unit by turning counterclockwise.
2. Connect a pressure gauge with Minimess hose to the Minimess test points (MM test
point) and check for absence of pressure.
3. Engage the rotor brake. Ensure that the following rotor brake magnetic valve is in the
initial position:
 HYDAC: Pos.4
 HAWE: Pos. 100.a (hand wheel 100.b turned left)
4. Check the pressure with a pressure gauge.
 HYDAC: Pos. 30 (knurled head screw relieved by turning left)
 HAWE: Pos.150
5. Disconnect leak-oil line from the leak-oil connection of the rotor brake.
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6. Disconnect leak-oil line from the pipe to the rotor brake on the drive train.
Fig. 45: Disconnect the hydraulic system from the rotor brake and from the drive train
1 Leakage oil connection at the

2 Pipe to the rotor brake
rotor brake
6.2 Removing the drive train
Eyebolt M12
6.2.1 Disassembling the M36 load rings at the rotor lock disk
Nacelle Electrically skilled person, technician
DANGER
The front side of the nacelle is open.
 It is mandatory to wear the PFPE and secure yourself to the personal

attachment points in the front area of the nacelle.
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Rev.: 00
DANGER
Life-threatening hazard from falling components
Fasteners may fall during removal.
 Ensure that there are no loose parts that may fall down.
 Provide load rings and M27 bolts with transport securements before starting
disassembly of the WT.
 Before starting disassembly, fasten transport securements on the rotor

lock disk.
 Assemble two M42 load rings and six M27 screws with transport securement each at the
rotor lock disk.
Fig. 46: Load rings at the rotor lock disk
2 M27 bolt with transport

1 M42–Lastbock
securement
6.2.2 Disassembling ALU rotor bearing lines
 The drive train is prepared for removal.
 The rotor lock is engaged in the rotor shaft.

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To facilitate the disassembly of the WT the drive train and nacelle are disassembled
separately. The nacelle may not be lifted by crane at the same time as the drive train.
DANGER
Bridge crane no longer to be used, as it is only allowed with the roof
fully assembled
DANGER
There is a risk of life-threatening injury from falling inside the nacelle after the drive
train has been lifted out of the nacelle.
 Always secure yourself to one of the personal attachment points marked

yellow with the PFPE when working in fall hazard areas at the nacelle.
Disassembling screw connections on the gearbox clamp halves
DANGER
Risk of injury from high pressure
The hydraulic cylinders are under high pressure.
 Stay clear of the danger area.

 Observe the safety notes in the manufacturer’s operating instructions
The disassembly of one gearbox support is described below. Perform the steps in a
similar manner for the other 3 gearbox supports.
1. Loosen 4 x collar nuts M42 and remove together with stud bolts M42 (1) and (2).
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Fig. 47: Screw connections on the gearbox clamp halves
2. Turn 2 x assembly screw connection M36 (3) and tighten securely.
3. Loosen remaining collar nuts M42 (4) and remove.
 Gearbox clamp halves have been released from the machine frame.
4. Loosen assembly screw connections M36 (3).
 Required pulling force to release: 2500 Nm
5. Remove assembly screw connections M36.
6. Lift the upper clamp half using the overhead crane and store securely in the nacelle.
7. Take off the upper coupling element and store it safely in the nacelle.
Disassembling screw connections on the rotor bearing housing
1. Loosen and remove 32 collar nuts M36 with stud bolts M36 on the rotor
bearing housing.
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Fig. 48: Assembled rotor bearing housing
2. Have 1 x collar nut M36 installed as guide for each side.
6.2.3 Removing the guard of the rotor shaft
Nacelle Technician
All components of the transport securement must be procured before disassembling

the WT.
The contact protection rotor shaft is moved by crane out of the nacelle together with
the drive train.
1. Disassemble all brackets between the contact protection and the machine frame.
2. Provisionally assemble the contact protection with transport securement on the

drive train.
 Assemble transport securement on the gearbox clamp halves.
Fig. 49: Load rings at the rotor lock disk
1 Transport securement
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6.2.4 Removing the nacelle roof
DANGER
Risk of falling from a great height
Fatal injuries.
 Before working outside the nacelle secure yourself with the PFPE at a
personal attachment point.
 Do not re-enter the nacelle roof after removal work has started.
Fig. 50: Attachment points for the four-strand chain sling
1. If option shadow flicker module, including bat -friendly, is available, remove electrical
connections on the nacelle roof.
2. Route lifting tackle and guide ropes upwards with the crane.
3. Attach the front nacelle roof to the four attachment points on the crane.
4. Guide rope with 20m of free-hanging rope upwards with the crane and fasten the rope
5. Close the access hatch.
6. Completely remove the front nacelle roof.
7. Lift the front nacelle roof together with the spinner transition hood in a horizontal
position with the crane, slew it and lower it to the ground.
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6.2.5 Attaching the drive train to the crane
 The drive train has been disassembled and rests with the pre-tensioned gearbox clamp
halves on the machine frame.
BOM component SAP no. Qty.
Shackle curved EN13889 WLL35t TypX 1018143 3
Curved shackle 55 t 60434 2
Round sling EN 1292-2 EWL 1.5m WLL 15t 8007279-XX 1
Sling chain 1 strand WLL 31.5t EWL 3m, w/ shortener, with 8025497-XX 1
shortening, with master-link at both ends
Round sling EN 1492-2 WLL 50t EWL 4m 8007282-XX 2
Round sling EN 1492-2 WLL 50t EWL 2m 8025496-XX 1
Round sling protector 0.5m 8019223-XX 5
Load ring M42 WLL 15 t - 2
Hex screw M27x240-10.9-tZn 8005923-XX 6
HV washer EN 14399-6-27-tZn 7120 6
Transport securement 8007336–XX 2
1. Disassemble the top ladder section of the yaw descent.
2. Attach the drive train with the lifting tackle to the main crane.
 Connect two lifting eyes marked in red at the gearbox to the lifting tackle.
 Connect two load rings at the rotor lock disk to the lifting tackle.
CAUTION
Material damage
If the guide rope is not properly fastened, the drive train can be damaged.
 Fasten the guide rope correctly.

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3. Fasten the guide rope to the rotor lock washer.
 The drive train is removed from the machine frame and completely attached
to the crane.
Fig. 51: Load rings and transport securement on rotor lock disk (similar to figure)
1 Load rings 2 Transport securement
Fig 52: Drive train attachment points (similar to figure)
1 Load rings at the rotor 2 Shackles to the lifting lugs on

lock disk the gearbox
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Fig. 53: Mesh center of gravity of the drive train
1 Shackle curved EN13889 2 Curved shackle 55 t

WLL35t TypX
3 Round sling EN 1292-2 EWL 4 Sling chain 1 strand WLL 31.5t
1.5m WLL 15t EWL 3m, w/ shortener, with
shortening, with master-link at
both ends
5 Round sling EN 1492-2 WLL 6 Round sling EN 1492-2 WLL
50t EWL 4m 50t EWL 2m
4. Attach additional tracking rope (10m) to the rear part of the drive train near the
oil pump.
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6.2.6 Removing the drive train
Transport frame, nacelle Technician
WARNING
Falling heavy loads
Serious injury due to falling or swinging of the lifted drive train.

 Make sure that 1 person in the nacelle is in constant radio contact with the
crane operator.
1. Make sure that the crane hook is suspended perpendicular above the center of gravity
of the drive train.
2. Lift the drive train.
 The drive train must lift equally from all four support surfaces. If needed, adjust the
length of the chain sling.
 The drive train must not swing. If necessary, change the position of the crane hook.
3. Repeat steps 1 and 2 until the drive train is suspended from the hook of the main crane
parallel to the support surfaces of the machine frame.
DANGER
Falling inside the nacelle
After removal of the drive train falling in the nacelle may result in life -threatening
injury.
 Hook the snap hooks of the PFPE into one of the personal attachment points
marked in yellow.
4. Carefully lift the drive train from the nacelle and lower it with the crane.
5. Lower the drive train onto the transport frame.

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6.2.7 Removing the supply and signal lines of the Bottombox
WARNING
Falling heavy loads
Serious injury due to falling or swinging of the lifted drive train.

 Make sure that 1 person in the nacelle is in constant radio contact with the
crane operator.
CAUTION: Do not disconnect supply cable of the Bottombox (cable W4502 5x162).
DANGER
Hazardous voltage

regulations.
 Disconnect all supply and signal lines in the Bottombox.
Disconnecting cables in box 8
CAUTION: Do not disconnect supply cable of the Bottombox (cable W4502 5x162).
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DANGER
Hazardous voltage

regulations.
 Disconnect all supply and signal lines in box 8.
6.2.8 Removing supply and signal cables
Tower base, nacelle Technician, electrically skilled person
DANGER
Risk of injury from falling objects
 Nobody may remain under the cables and in the tower when lowering the
supply and signal cables.
An external service winch is needed to remove the supply and signal cables, since the
electrical winch has already been removed at this moment in the disassembly.
1. Hook the service winch on the third hole of bracket 1.
2. Utilize the power supply in the tower for the service winch.
3. Lower the service winch until reaching the bottom eyelet of the cable support grip.
4. Absorb load so that the upper eyelet of the cable support grip can be unhooked.
5. Fix the FO cable to the cable bundle with cable ties and then lower it to the flange
platform of the lowest MID section.
6. Mechanic climbs downwards to the flange platform bottom MID section.
7. Decouple cable from the service winch.
8. Coil all cables separately from each other and secure for transport.
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7 Nacelle
7.1 Preparing the removal of the nacelle
 The nacelle roof has been removed.
 The drive train has been removed.
7.1.1 Preparing the depositing space for the nacelle
Depositing space on the ground Technician
 On a prepared support surface (“elephant feet”), set up and align 2 turbine -specific
transport feet each at the front and rear according to the fit in the nacelle . If necessary,
create a template for this.
 Distance of transport feet according to E0004767904 7050mm
7.1.2 Aligning the nacelle
DANGER
Electric voltage
Any contact with live parts may result in death or serious injury.

regulations.
 Move the nacelle via the control panel on the AUR1 yaw converter (master) so that the
nacelle is positioned transverse to the crane (long side parallel to the crane jib).
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7.2 Attaching the nacelle to the crane
Machine frame Technician
After the drive train has been disconnected and removed from the machine frame, the
preparations for removing the nacelle can start. A 4 point lifting tackle can be used to
attach the nacelle to the generator frame.
The crane hook of the main crane must be exactly above the ce nter of gravity of the
nacelle after attaching. This is located as shown in the figure below.
The nacelle is attached from 2 attachment points at the machine frame and the
generator frame. When the nacelle has been released from the tower flange, it should
hang correctly in the crane hook immediately when it is lifted. Later readjustment is
not possible or only with great effort.
Fig. 54: View from top nacelle

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7.2.1 Attaching the guide ropes
WARNING
Falling guide ropes
Risk of serious injury due to falling guide ropes.
 Only release and lower the guide ropes from the nacelle after consultation
with the people on the ground. Do not throw them down.
 When lowering: Maintain a safe distance.
The guide ropes are routed upwards from the ground with the nacelle fastening
equipment. The front guide rope is now fastened to the ground and is no longer
transposed overhead. After installing the rear guide rope on the back of the nacelle,
it must be possible to release the guide rope from the crane hook.
Do not run guide ropes over person attachment points.
1. Attach the front guide rope to the fastening equipment.
2. Attach the rear guide rope to the fastening equipment so that 10m of the upper end
hangs loose.
3. Lead the fastening equipment upwards.
4. Fasten the guide rope to the nacelle.
5. Slew the crane to the fastening points of the nacelle and fasten the nacelle to
the crane.
6. When lowering the nacelle with the crane, guide using guide ropes from the ground.
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Fig. 55: Attaching the guide ropes
A. To the shackle at the bottom B. On the right strut of the

of the chain cooling system frame
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7.2.2 Attaching the nacelle to the crane
Machine frame Technician
Fig. 56: Attaching the nacelle to the crane
A. Chain sling generator B. Chain sling machine frame

1 Shackle curved EN13889 WLL35t TypX 2 Curved shackle 55 t
4 Sling chain 1 strand WLL 31.5t EWL 3m,
3 Round sling EN1492-2 WLL 15t EWL 3m w/ shortener, with shortening, with
master-link at both ends
6 2-strand Cartec 100 chain sling, WLL 38t
5 Round sling EN 1492-2 WLL 50t EWL 2m
EWL 1.88 m with round sling coupling
8 Round sling EN 1492-2 WLL 20t EWL
7 Round sling EN 1492-2 WLL 50t EWL 4m
2.5m
1. Chain sling machine frame: Attach 2 attachment points to the main crane, see detail B.
 2 x curved shackle WLL 35 t
 Pull 1 x round sling WLL 15 t / EWL 3 m twice through the shackles on the
adjustable chain.
 1 x curved shackle 35 t
 1 x adjustable chain sling WLL 31.5 t; EWL 3 m; adjust the chain sling to a length of
approx. 2 m.
 Pull 1 x round sling WLL 40 t; EWL 2 m through the chain eye and hook it twice over
the crane hook.
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2. Chain sling generator frame: Attach 2 attachment points to the main crane, see detail A.
 Left side:
 1 x round sling 40 t; EWL 4 m
 Right side:
 1 x round sling WLL 40 t; EWL 2 m
 Adjust 1 x 2 strand Cartec 100 chain slings to total length of 3.9 m
 (crane hook requirement until lower round sling)
 1 x round sling WLL 20 t, EWL 2.5 m
3. Adjust both chain slings so that the nacelle is slightly inclined forwards.
7.3 Disassembling the nacelle
7.3.1 Disassembling the nacelle
Top section Technician
 Depositing space for the nacelle has been prepared.

 Transport supports with guide pins on the depositing space are positioned.
CAUTION
Risk of injury and material damage if HV screws, washers and HV nuts
are reused
If HV screws, washers and HV nuts are reused, the safety of the new connection is
no longer guaranteed.
 Dispose of removed HV screws, washers and HV nuts.
Operating instructions E0004767904 Transport device for the nacelle

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1. Attach pre-adjusted hanger in the nacelle.
2. Take crane to 5 t load.
3. Align hanger and crane hook and if needed readjust.
4. Leave nacelle.
5. Have the crane pick up the weight of the NAC.
6. Loosen M20 screws except for 2 bolts each at 12, 3, 6 and 9 o’clock positions and check
that NAC is lifted in parallel.
7. Screw on guide pins.
 1 x guide pin M20x380 in 12 o’clock position
 1 x guide pin M20x340 in 6 o’clock position
Fig. 57: Guide pins
1 Guide pin 12 o’clock position 2 Guide pin 6 o’clock position
8. Increase crane load slowly and check whether nacelle stands out in parallel from the
tower flange.
9. If NAC is lifted generator side first: Remove all M20 screws from the flange connection
and lift nacelle.
10. If NAC is not lifted generator side first: Set down nacelle again and tighten all
M20 screws of the flange connection again with 315 Nm. Readjust hangers and repeat
steps 3-8.
11. M20 screw may be reused for the above st eps. After disassembly of the NAC, the M20
screws must not be reused and must be disposed of.
12. Store M20 screws securely in a suitable bag/box

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7.3.2 Removing the bottom ladder section
Nacelle Technician
DANGER
Moving components
When disassembling the bottom ladder section, a rotating nacelle can lead to
severe injuries.
 Rotor lock is engaged.

 Yaw system shut down.
1. Leave the nacelle.
2. Disassemble the lower ladder component from the yaw access ladder.
7.3.3 Take off the nacelle
Transport frame, nacelle Technician
DANGER
Falling heavy loads
Serious injury due to falling or swinging of the lifted nacelle.

 Ensure that a person on the work platform is in constant radio contact with
the crane operator.
1. Slowly lift and crane off the nacelle
2. Lower the nacelle onto the transport frame

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8 Removing the cooler
On the ground Technician
8.1 Preparatory measures
 Prepare a transport pallet with a counterweight.
8.2 Draining the cooling water
Nacelle Technician
CAUTION
Risk of injury and material damage if HV screws, washers and HV nuts
are reused
If HV screws, washers and HV nuts are reused, the safety of the new connection is
no longer guaranteed.
 Dispose of removed HV screws, washers and HV nuts.

 Wear safety goggles while working.
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Fig. 58: Example of a water cooling system passive cooler

(structural deviations possible)
2 Ball valve at right rear

1 Ball valve under rear
between transformer
nacelle roof
and converter
1. Close ball valves on passive coolers
 Position passive cooler connection: Close 4 x under rear nacelle roof
2. Check the pressure gauge of the cold water pump to see whether there is no pressure
in the cold water system:
3. Close the ball valves in the nacelle.
 Position nacelle connection: 2 x at right rear between transformer and converter.
4. Disconnect cooling circuits between the ball valves, under the passive cooler
connection, and collect escaping cold water.
5. Dispose of cold water properly.

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8.3 Disassembling the cooling system frame
Nacelle Technician
DANGER
DANGER
Falling objects
Risk of life-threatening injuries from items falling down from the WT.
 Establish a security zone around the wind turbine.

 Remove any loose items.
WARNING
Risk of tilting
If the cooling system frame is installed alone on the transport pallet, the pallet may
tip over.
 Ensure that there is a counterweight or attach brace.
WARNING
Sharp lightning rods on obstacle lights
Cutting injuries when working at the cooling system frame.
 Disassemble the lightning rods before working at the cooling system frame.
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1. Disconnect properly all cables from the nacelle to the cooling system frame.
 Loosen plugs on the sensors.
 Disconnect cables in the Topbox.
2. Disassemble two covers for the cooling system duct on the nacelle roof.
3. Pull all option cables through the additional screw connection out of the nacelle in the
direction of the cooling system frame, roll them up there and secure them.
4. Attach the cooling system frame to the crane.
5. Disassemble the cooling system frame.
6. Lift the cooling system frame carefully vertically from the nacelle. Make sure that the
option cables are led out in the middle bar of the cooling system frame.
7. Ensure that the ball valves do not remain suspended on the nacelle roof.
8. Move the cooling system frame by crane and lower it onto the transport frame and
secure it.
9. Disassemble the lightning rods on the cooling system frame.
10. Disassemble lightning rod brackets.
11. Dismantle wind measuring mast and sensor system and pack securely in bubble wrap
and label.
12. Remove all existing options and wrap securely in bubble wrap and label.
8.4 Removing wind measuring mast and lightning protection bracket
Ground Technician
If the lightning protection receptors and measuring instruments are to be reused, pack
them in shockproof packaging and transport them carefully, for example inside the
nacelle. The met mast is transported in its own transport frame.
1. Fasten met mast and lightning protection bracket on the transport frame.
2. Pack the wind sensors and sensor cables.
3. Pack all available options including cables.
4. Transport the options including cables in the corresponding switch cabinet in the nacelle
or in a similar suitable way.
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9 Options
Wind turbines from the Delta4000 product series can have
optional equipment. These disassembly instructions do not include information on how to
remove these options. All sensors to be removed must be wrapped in bubble wrap and labeled.
All cable ends must be covered accordingly. The components must then be stored in a dry
place. All fasteners must also be kept and stored.
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10 Precast concrete hybrid tower
The disassembly of the precast concrete hybrid tower follows the disassembly of the nacelle.
 The precast concrete hybrid tower consists of a precast concrete part as tower base,
a tubular steel MID section and a tubular steel top section. The MV gearbox is
positioned in the tower base on a gearbox platform.
10.1 TCS tower: Downtimes during removal
DANGER
Collapsing tower
There is a risk of fatal injury resulting from collapse of the tower due to tower
vibrations and incorrect removal of the tower’s screw connections.
 Pay attention to downtimes when interrupting the disassembly of the tower.
Do not exceed the following downtimes to ensure stability and fatigue strength:
N149/4.X TCS164 (NV06)
Max. time until the disassembly condition

Achieved disassembly condition
below has been reached
Without top section 365 days
Without nacelle 365 days
Hammer head (with or without rotor hub) 365 days

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Achieved disassembly Max. time until Working on Measure as long as

condition the disassembly the WT and wind exceeded
condition below has staying in
been reached the WT
MID section 30 days VWind ≤ 9 Stop disassembly,

leave WT
Top section 30 days VWind ≤ 7 Stop disassembly,

leave WT
Nacelle without 30 days VWind ≤ 7 Stop disassembly,

drive train leave WT
Nacelle with drive train 30 days VWind ≤ 7 Stop disassembly,

without hub leave WT

and hub leave WT

and hub and leave WT
one/two/three blades
VWind describes the 10-minute mean value for the wind speed at the highest point of the
turbine in the respective disassembly condition. On site the 10-minute mean value for the
wind speed can be approximated at the crane jib. If the specified wind speed limits are
exceeded tower vibrations may occur perpendicular to the direction of attack.
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10.2 TCS tower: Tower screw connection tightening torques
DANGER
Collapsing tower
 As long as the top section is still on the tower keep the safety -relevant screw
connections of the tower to 100 % of the required tightening torque.
 Also keep the safety-relevant screw connections of the tower to
100 % of the required tightening torque when interrupting the
disassembly of the tower sections.
N149/4.X TCS164 (NV06)
The guide ropes are routed upwards from the ground with the nacelle fastening
equipment. The front guide rope is now fastened to the ground and is no longer
transposed overhead. After installing the rear guide rope on the back of the nacelle, it
must be possible to release the guide rope from the crane hook.
Screw connections Screw size Tightening torque [Nm]
MID/top section M36 2800

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11 Top tower sections
11.1 Removing the service lift

The service lift of the wind turbine is manufactured by Hailo. To remove the service lift,
observe the documentation of the service lift manufacturer.
Hailo TOPLift
 E0004329816 Hailo TOPLift L+ Assembly instructions
 K0802_058150 Assembly instructions Hailo TOPLift L
Current circuit diagram
 Circuit diagram Electrical installation - Tower
DANGER
Risk of falling from a great height
Risk of fatal injury resulting from incorrect use and removal of the service lift.
 Only have the service lift removed by specially trained personnel of a

company authorized by the manufacturer.
DANGER
Risk of falling due to missing locks
Risk of fatal injury if the interlocking system is removed.
 Do not move the lift cabin if the locks at the railing door are removed or
not operating.
 When working on the platforms, secure yourself to the personal attachment
points with the PFPE.
DANGER
Crushing hazard under the lift cabin
Standing under the lift cabin can lead to life-threatening injuries.
 Do not access the area of the access platform under the lift cabin.
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DANGER
Risk of injury from collision of the lift cabin with other objects
 Do not deposit anything on the access platform under the lift cabin.
11.1.1 Securing service lift in the tower base
Tower base Technician
Hailo TOPLift
 E0004329816 Hailo TOPLift L+ Assembly instructions
 K0802_058150 Assembly instructions Hailo TOPLift L
1. Secure service lift above the tower access platform on the vertical ladder.
Fig. 59: Hydraulic unit block HYDAC
1 First vertical ladder bracket 2 Ladder rung below the first

vertical ladder bracket
2. Secure service lift with the upper pair of board rollers on the first vertical ladder bracket
or on a ladder rung below it, see Document E0004329816 or Document K0802_058150.
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11.1.2 Removing steel ropes and lift cables
Tower Technician
The suspension rope and the safety rope of the service lift platform are mounted to a crossbeam
in the top section above the service lift platform. They are tightened in the bottom section below
the access platform with cable weights. The suspension rope and the safety rope are guided
through the lifting hoist at the lift cabin and through the cable-guide carriage below the lift cabin.
The lift cable connects the distribution box in the tower with the lift cabin. As the cabin moves
up and down, the lift cable follows its movements via the cable -guide carriage in the tower. The
distribution box is located approximately in the center of the tower on the level of the middle
platform.
DANGER
Falling steel cables
Fatal injuries due to incorrect disassembly.
 First release the steel cables at the bottom of the tower, then pull them up to
the top section.
 Do not release the steel cables from the crossbeam before they are securely
attached on the lift platform in the top section.
DANGER
Electric voltage

regulations.
Do not reuse steel cables removed from the service lift rules.
1. Remove the cable weights as described in the manufacturer’s documentation.
2. In the individual sections, cut the rope and fasten it to the grounding point of the lower
flange of the upper flange connection by means of rope clamps (8-9mm) and an
eyebolt (M16)
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3. Deactivate the service lift.
 Verify that the service lift is dead.
4. Attach the lift cable to the cabin in the tower base.
5. Pull the lift cable up to the middle platform at the level of the service lift distribution
box, loop the cable and secure it on the railing.
6. Disconnect the lift cable between the distribution box and the cable suspension on the
platform railing of the middle platform.
11.2 Removing the top section
The following chapters specify the disassembly sequence for the top section which is
also applicable for the following mid sections. All information refers to the currently
highest tower section.
DANGER
Collapsing tower
 Leave the safety-relevant screw connections of the top section tightened

to 100 % of the required tightening torque until the top section is attached
to the crane.
DANGER
Heavy load
Risk of fatal injury from swinging tower section.
 Observe a safety distance from the tower section when it is lowered by crane.
DANGER
Falling objects
Risk of serious injury from items falling out of the tower section.
 Remove any loose objects from the tower section before lowering it by crane.
 Observe a safety distance from the tower section when it is lowered by crane.
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11.2.1 Attaching a tower section to the crane
Top tower section Technician
Fig. 60: LLA positions at the top and bottom tower flanges
1 LLA bottom tower flange: 2 LLA top tower flange: Outside

Inside lifting lug (auxiliary lifting lug (main crane)
crane)
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Fig. 61: LLA positions at the top and bottom tower flanges
1 LLA bottom tower flange:

2 LLA top tower flange:
Inside lifting lug
Outside lifting lug (main crane)
(auxiliary crane)
3 Oil-proof platform ladder 4 Access ladder
 Position of the LLA for the upper tower flange: Center of LLA 40 drill holes clockwise
and counterclockwise from 0° position (red dot or center punch, sometimes difficult to
see).
 Position of the LLA for the lower tower flange: Center of LLA 80 holes clockwise from
0° position (red dot or center punch, sometimes difficult to see).
 Securely store bag/box with screws on the side of the access ladder (tower).
 Attach the tower section to a suitable crane.
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11.2.2 Preparing the top section for disassembly
Bottom tower flange of the top tower

section Technician
1. Have main crane pick up approximately 90% of top section weight load.
2. Descend to the top platform of the next lower tower section.
DANGER
Removed fall arrest system
Risk of fatal injury from falling without fall arrest system.
 Do not use the vertical ladder without PFPE.

 Use the snap hook of the energy absorber alternately to secure yourself.
 Always attach the snap hooks to the beams of the vertical ladder – never to
the rungs.
 Before moving the snap hook, secure yourself with the second fastener.
3. Remove the rail connectors of the fall arrest rail at the tower joint.
4. Remove the connectors of the vertical ladder.
5. Mount the end piece for the fall arrest rail.
DANGER
High electrical voltage
Electric shock resulting from incorrect handling of electrical equipment.
 Only remove the grounding jumpers immediately before lowering the

tower section.
6. Release and remove 4 flange grounding plates per tower flange.

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11.2.3 Releasing and removing the tower screw connections
Bottom tower flange of the top tower section Technician
 The top tower section is attached to the main crane.
 The main crane has picked up approx. 15 t of weight.
Procedures for removing screws:

 Torque-controlled releasing (e.g. Hytorc)
 Hydraulic releasing (e.g. ITH)
Removed HV screws, washers and nuts are not intended for reuse.
 Dispose of removed HV screws, washers and nuts.
1. Prepare the hydraulic tool.
2. Loosen all screw connections with clamping cylinder one after the other and tighten 3
bolts each in 12, 3, 6 and 9 o’clock position immediately with an impact wrench.
3. Mount 3 guide pins (M36x300) at a 120 degree angle.
 When releasing the screws, mount the guide pins while more than half the screw
connections are still in place.
 Insert the guide pin into the hole that opens up when the screw is removed.
4. Crane load to 100% of the top section weight.
5. Loosen remaining screws gradually until a gap of 1-2cm can be seen.
6. Deposit the HV screws, washers and nuts on the flange platform all around.
7. Disconnect the plug connection for the power supply in the tower.
8. Release the top tower section from the tower flange using the main crane and lift it
straight up.
11.2.4 Setting down top section and store safely
Tower section Technician

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 The wooden structure on which the tower section is to be set down standing up
is prepared.
1. Move the upper tower section with the main crane.
2. Lower the tower section to approx. 1.5 m above the ground.
3. Position the tower section vertically over suitable support stands and set it down.
4. Mount the LLA for the auxiliary crane on the lower tower flange opposite the
access ladder.
 Determine the position for the LLA on the lower bottom tower flange.
5. Attach the tower section to the bottom tower flange.
6. Raise tower section with main crane to a vertical height, allowing free rotation
and slewing.
7. Bring the tower section into a horizontal position.
8. Place tower segment on transport device and secure (each side one Bongossi and one
bearing shell).
9. Remove LLA from tower.
12 TCS tower: Tower base

In the TCS tower, the tower base is made of precast concrete components.
12.1 Disconnecting the nacelle supply cable
 Disconnect the nacelle supply cable.
12.2 Disconnecting the cables at the tower flange transition
 Disconnect cables on the tower flange transition to A2-E Box.

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12.3 Disconnecting wire mesh cable tray from steel adapter
1. Disconnect 4 x wire mesh cable trays from bracket wire mesh cable tray.
12.4 Disassembling tower base installations
 Disassemble tower base installations. These include:

 Bottombox
 Switchgear
 Splice box
 Emergency stop
 Light switch
 External lamp
 Grounding cables
 Cable guides and wire mesh cable trays
 Further options
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13 Final work
13.1 Transporting and storing operating materials/hazardous

substances
Sales document; lubricants, coolants, transformer oil and measures against accidental
leakage, for all class Delta4000 Nordex wind turbines
For an overview of the types and quantities of operating materials/hazardous substances in the
wind turbine, see chapter 2.6 “Safe handling of hazardous substances/operating materials”.
1. Collect all operating fluids/liquid hazardous substances in suitable containers, store

them and transport them to the collection point.
2. Ensure that all operating fluids/liquid hazardous substances have been removed from
the assemblies of the wind turbine.
3. Commission an authorized service provider to dispose of the operating

materials/hazardous substances professionally.
13.2 Removing Nordex equipment and the substation

1. Remove all cables leading to the SCADA cabinet and CWE cabinet.
2. Disassemble and remove the SCADA cabinet.
3. Disassemble and remove the CWE cabinet.

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14 Appendix
14.1 Tools
The following table provides an overview of the special tools and accessories required for
removing the WT. Site cleanup will be specifically discussed at each site kick-off. Basic tools
are not provided by Nordex. Specific tools, which can be found in the table below, are provided
by Nordex for disassembly.
BOM component Spec.
General
Container for cleaning rags and liquids -
Waste, scrap containers -
10 long (5 m) Bongossis, 4 short (2 m)

Safety package
Bongossis
20x Bongossis -
Boxes / bags for bolts -
Drone -
Laser range finder -
Rotor blade
Root cradle Incl. Fasteners
Tip, tip base Incl. Fasteners
Certex blade lifter -
Holding ropes or guide ropes Min. 250 m
Centering pin -
Edge protection -
Telescopic rod with hook -
Rotor hub
Hub transport frame Incl. Fasteners
Hub bogie Incl. Fasteners
Bearing frame spinner parts (Wooden pallets for spinner parts)
Turning drive -
Tarpaulin, welding foil -
Drive train
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Lifting safety device drive train/rotor lock -
Hoisting device e.g. swivel hoist rings
Transport frame – drive train Incl. Fasteners
Rotor shaft guard transport securement -
Nacelle
Transport supports (front, back) Incl. Fasteners
Support stands - NAC roof -
Cooler
Cooler pallet Counterweights, accessory boxes
Packaging material - sensors -
Cooler frame -
Switchgear
Transport trolley for the electrical

-
components
Pallet for switchgear -
Lift
Rope clamps 8-9 mm
Transport device -
Pallet -
Bottombox
Bottombox frame -
Bottombox packaging -
MV cable -
Scissors to separate the MV cable -
Tubular steel section
Transport device tower top section Min. 5 support stands

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14.2 Weights
The specified weights are guideline values. Refer to the erection or transport instructions for
the exact values for the wind turbine to be dismantled. The weight may deviate slightly from
the values specified below due to different manufacturers. The specified weights of the tower
sections may vary by ±5 %.
Designation Weight [t] TCS164 (NV06)
Rotor hub Max. 63.6/ 66.7 (without/with transport frame)
Rotor blade (per blade, varies

Max. 21
depending on the manufacturer)
Nacelle without drive train and

Max. 69.0/70.2 (without/with transport frame)
without rotor
Drive train (rotor shaft, gearbox) Max. 73.3/75.9 (without/with transport frame)
Nacelle, complete (without rotor) Max. 142.3
Converter cabinet Approx. 2.9
Medium-voltage transformer Approx. 10.0
Medium-voltage switchgear Approx. 2.0
Max. section weight 53

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14.3 Technical data

For more information refer to the transport instructions and operating instructions.
Climatic design data of the standard version
Description N149/4.X
Survival temperature –40 to +50 °C
Operating temperature range

–20°C to +40 °C 1)
Operating temperature range

–30°C to +40 °C 1)
CCV
Standard -20 °C, restart at -18 °C

Stop
CCV -30 °C, restart at -28 °C
Max. height above MSL 2000 m1)
Certificate In accordance with IEC 61400-1 and DIBt 2012

1 ) Nominal power is achieved up to defined temperature ranges depending on the power factor.
Technical design
Type 3-blade rotor with horizontal axis, up-wind turbine
Output control Active single blade adjustment
Nominal power Variable 4000–4500 kWb
Rated power at wind speed (at an

Approx. 11.5 m/s
air density of 1.225 kg/m3 )
Speed range of rotor 7.5 to 13.6 rpm
Nominal speed 11.0 min- 1
Cut-in wind speed 3.0 m/s
Cut-out wind speed 26.0 m/s
Cut-back-in wind speed 25.5 m/s
Calculated service life At least 20 years

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Rotor
Rotor diameter 149.1 m
Swept area 17460 m2
Nominal power / area 257.7 W/m2
Rotor shaft tilt angle 5°
Blade cone angle 3.5 °
Rotor hub
Material Spheroidal graphite cast iron EN-GJS-400-18-LT
Rotor blade
Glass-fiber reinforced and carbon-fiber reinforced

Material
plastic
Total length 72.4 m
Rotor shaft / bearing
Type Forged hollow shaft
Material 42CrMo4 or 34CrNiMo6
Bearing type Spherical roller bearing
Lubrication Regularly using lubricating grease
Rotor bearing housing material Spheroidal graphite cast iron EN-GJS-400-18-LT

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Gearbox
Type Multi-stage planetary gear and spur gear stage
Nominal power P nG up to 4800 kW

50 Hz: 1:113.5
Gear ratio
60 Hz:
1:136.2
Lubrication Forced-feed lubrication
Oil quantity including cooling circuit Max. 650 l
Oil type ISO VG 320
Max. oil temperature 77 °C
Oil change Change, if required
Electrical system N149/4.X
Description 660 V AC 690 V AC
Nominal power P nG up to 4500 kW up to 4800 kW
3 x AC 660 V ± 10 % 3 x AC 690 V ± 10 %
Nominal voltage
(specific to grid code) (specific to grid code)
Nominal current InG at SnG 4503 A 4571 A
Nominal apparent power S nG at PnG 5148 kVA 5463 kVA
1.00 as default setting 1.00 as default setting
0.869 underexcited 0.8785 underexcited

Power factor at P nG (inductive) up to (inductive) up to
0.885 overexcited 0.8785 overexcited

(capacitive) possible (capacitive) possible
Frequency 50 or 60 Hz
Doc.: 2030290EN
Rev.: 00
The nominal power is subject to system-specific tolerances and varies by ± 100 kW.
Practice has shown that negative deviations occur rarely and in most cases are
<25 kW. In order to precisely comply with external power specifications, the nominal
power of the wind turbine can be defined by means of parameters. Alternatively, set
the parameters for the wind farm accordingly using the Wind Farm Portal.
Generator
Degree of protection IP 54 (slip ring box IP 23)
Nominal voltage 660 V/ 690 V
Frequency 50 or 60 Hz
50 Hz: 730 to 1390 rpm

Speed range
60 Hz: 876 to 1668 rpm
Poles 6
Gearbox cooling and filtration
1st cooling circuit: Oil circuit with oil/water heat exchanger

and thermal bypass
Type
2nd cooling circuit: Water/air combined with generator,
main converter and thermal bypass
50 Hz: 5.0/7.5 kW
Gear oil pump, 2-stage
60 Hz: 5.7/8.6 kW
Level 1: approx. 100 l/min

Flow rate
Stage 2: approx. 200 l/min
Coarse filter 50 µm
Filters Fine filter 10 µm
Fine filter <5 μm
Offline filter (optional) 3 μm

Doc.: 2030290EN
Rev.: 00
Generator and converter cooling
Water circuit with water/air heat exchanger and

Type
thermal bypass
Flow rate Approx. 160 l/min
Coolant Water/glycol-based coolant
Transformer cooling
Variant 1: Ester circuit with ester/water heat exchanger

1st cooling circuit
Variant 2: Sealed air circuit with air/water heat exchanger
2nd cooling circuit Water/air combined with generator, converter and gearbox
Mechanical brake
Type Actively actuated disk brake
Location On the high-speed shaft
Number of brake calipers 1
Brake pad material Organic pad material
Pitch system
Pitch bearing Double-row four-point contact bearing
Gearing lubrication Automatic lubrication unit with grease
3-phase motor incl. spring-actuated brake and multi-stage

Drive
planetary gear
Emergency power supply Gel batteries

Doc.: 2030290EN
Rev.: 00
Hydraulic system
Hydraulic oil Shell Tellus S4 VX 32 or comparable
Oil quantity Approx. 25 l
Hydac
- 50 Hz: 1.5 kW
- 60 Hz: 1.73 kW
Nominal power of the
hydraulic pump
Hawe
- 50 Hz: 2.1 kW
- 60 Hz: 2.16 kW
Nacelle material
Machine frame Spheroidal graphite cast iron EN-GJS-400-18U-LT
Material of generator frame

Satisfying
and steel framework
Nacelle housing material Glass-reinforced plastics (GRP)
Yaw bearing
Type Ball bearing
Material 42CrMo4
Yaw drive
Motor Asynchronous motor
Gearbox 4-stage planetary gear
Number of drives 4
Lubrication Oil, ISO VG 150
Oil quantity Approx. 27 l
Yaw speed Approx. 0.5 °/s

Doc.: 2030290EN
Rev.: 00
N149/4.X precast concrete hybrid tower
Description TCS164 (NV06)
Hub height 164 m
Wind class DIBt S
Number of tower sections 1 x concrete part, 2 x tubular steel tower
Material Tubular steel tower: EC: S355
Corrosion protection Tubular steel tower: Multilayer epoxy resin coating

2030290EN 00 Docx 2030290EN 0 Disassembly Instructions D4K N149 NV06

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- Translation of the original document (2030290DE, rev. 00) -

Done Reviewed Approved

01-11-2022 01-11-2022 01-11-2022

© 2022 NORDEX GROUP. All rights reserved.

DISASSEMBLY INSTRUCTIONS Page: 2 / 134

All rights reserved.

 2022 Nordex Energy SE & Co. KG, Hamburg

Manufacturer’s address as per Machinery Directive:

Nordex Energy SE & Co. KG

Langenhorner Chaussee 600

Tel: +49 (0)40 300 30 -1000

Fax: +49 (0)40 300 30 -1101

Please refer to the last page for document information!

DISASSEMBLY INSTRUCTIONS Page: 3 / 134

Delta4000 N149/4.X TCS164 (NV06)

DISASSEMBLY INSTRUCTIONS Page: 4 / 134

Rev. Date Author Reason for revision / chapter AST

00 2022-10-07 J. Pape/Intec New revision 25778

DISASSEMBLY INSTRUCTIONS Page: 5 / 134

1.2 Target group 10

1.3 Signs and symbols used 11

1.4 Design of the warning notes 12

1.4.1 Warning notes 12

1.4.2 Warning levels 12

1.7 Applicable documents 14

2.1 General safety instructions 15

2.2 Wind turbine safety devices 15

2.3 Access to the WT 16

2.4 Personal protective equipment 16

2.5 Working on the wind turbine 16

2.5.1 Preventing electric shock from electrostatic charge 16

2.5.2 Preventing electric shock during thunderstorms 16

2.5.3 Preventing falls when working on the wind turbine 17

2.5.4 Working on and inside the rotor hub safely 17

2.5.5 Working on the drive train safely 18

2.5.6 Working safely with high-stress screws 18

2.5.7 Protection against falling objects 18

2.5.8 Using the crane safely on the WT 19

2.5.9 Wind speed 20

2.5.10 Insects and arachnids 21

2.6 Safe handling of hazardous substances/operating materials 21

3 Pre paring for disassembly 25

3.1 Providing the lifting tackle 25

3.2 Preparing the WT 25

3.2.1 Required securements switched on 25

DISASSEMBLY INSTRUCTIONS Page: 6 / 134

3.2.2 Disconnecting transformer 27

3.2.3 Disconnecting cable connection MV switchgear 27

3.2.4 Disconnecting cable connection MV switchgear 28

3.2.5 Establishing the portable power supply 28

3.2.6 Assembling and positioning transport frames 29

3.2.6.2 Transport frame – rotor hub 29

3.2.7 Setting the pitch tower damping 30

3.3 Bringing devices, tools and materials to the nacelle 32

3.4 Removing the coupling contact protection 32

3.5 Disassembling the slip ring unit 34

3.5.1 Removing the slip ring cable 34

3.5.2 Disassembling the slip ring unit 34

3.6 Disassembling the generator coupling 36

3.7 Installing the turning drive in the nacelle 38

3.8 Disconnecting the MV cables 38

3.8.1 Disconnecting MV cable from MV switchgear 39