Mechanical Component Repairs and Replacements
Comprehensive mechanical service for wind turbines – from drivetrain repairs and component replacements to specialist gearbox work. All services performed by GWO-certified technicians according to OEM procedures and safety standards.
Keeping your turbines running through expert mechanical service
The mechanical drivetrain is the heart of every wind turbine. From the main bearing through the gearbox to the generator – every component must operate reliably under extreme conditions: high loads, variable speeds and continuous operation.
Our mechanical service team specialises in both routine repairs and complex specialist work. We perform up-tower repairs wherever possible, minimising downtime and avoiding costly major component replacements. When component replacement is necessary, we ensure precise installation in accordance with OEM specifications.
Comprehensive mechanical service
Drivetrain Component Service
The drivetrain transfers rotational energy from the rotor to the generator. We service all major drivetrain components across multiple turbine platforms.
Gearbox service:
• Oil changes and filtration system maintenance
• Internal inspection and borescope examination
• Bearing replacements (where up-tower feasible)
• Bushing replacements (Vestas V112–V150 specialist)
• Seal replacements and leak repairs
Generator service:
• Bearing replacements (DE and NDE)
• Cooling system maintenance
• Brush and slip ring service (where applicable)
• Alignment verification
Main bearing and couplings:
• Main bearing greasing and monitoring
• Coupling inspection and replacement
• Shrink disc maintenance
• Alignment checks and corrections
Pitch and Yaw System Service
Pitch and yaw systems control blade angle and nacelle orientation. Reliable operation is essential for power optimisation and safety.
Pitch system:
• Pitch motor and gearbox repairs
• Pitch bearing inspection and greasing
• Battery backup system service
• Encoder and sensor calibration
• Emergency feathering system verification
Yaw system:
• Yaw motor and gearbox service
• Yaw bearing inspection and greasing
• Yaw brake pad replacement
• Yaw damper inspection
• Cable twist monitoring and correction
Both systems require regular maintenance to prevent failures that could result in turbine shutdown or safety incidents.
Hydraulic System Service
Hydraulic systems are critical for turbine safety and controlled operation.
Brake system service:
• Brake pad inspection and replacement
• Brake disc condition assessment
• Brake caliper service
• Rotor lock mechanism maintenance
• Emergency brake system verification
Hydraulic component service:
• Hydraulic pump service and replacement
• Cylinder repairs and seal replacements
• Accumulator inspection and pre-charge
• Valve maintenance and replacement
• Hydraulic oil changes and filtration
• Leak detection and repair
• Pressure testing and system diagnostics
All brake and hydraulic work follows strict safety procedures with proper system isolation and verification testing.
Repairs and replacements across all mechanical systems
• HSS gearbox shaft bearings – replacement and alignment
• Gearbox bushings – Vestas specialisation
• Intermediate shaft bearings
• Seals and gaskets
• Oil pumps and filtration
• Gearbox mounts and dampers
• Torque arm bushings
• Internal gear inspection
• Generator bearings – DE and NDE
• Main shaft bearings
• Pitch motor gearboxes
• Yaw motor gearboxes
• Cooling fan motors
• Hydraulic pump motors
• Couplings – flexible and rigid
• Shrink discs and hubs
• Hydraulic cylinders
• Hydraulic pumps
• Hydraulic accumulators
• Control valves
• Proportional valves
• Brake calipers
• Hydraulic hoses and fittings
• Filters and reservoirs
Expert service for Vestas V112–V150 gearboxes
We have developed defectoscopy analysis capabilities in Vestas gearbox service, which we also use for gearbox bushing wear inspection on V112–V150 turbines. This specialist work requires precision, knowledge of design and strict adherence to OEM procedures.
Specialist bushings replacement in Vestas gearboxes requiring excellent knowledge of gearbox design and OEM procedures.
Models covered:
V112, V117, V126, V136, V150
Assembly tolerances:
• Radial clearance: 0.05–0.12 mm
• Axial clearance: max. 0.08 mm
• Surface roughness: Ra ≤ 0.8 μm
Work includes complete gearbox preparation, precision bushing installation, clearance verification and operational testing.
High Speed Shaft bearing replacements on Vestas and other OEM gearboxes, critical for drivetrain reliability.
Indications for replacement:
• Elevated vibration levels
• Abnormal CMS readings
• Increased operating temperatures
• Metal particles in oil analysis
• Mechanical noise
We perform HSS bearing replacements up-tower with full alignment verification, minimising downtime compared to gearbox exchange.
Structured methodology for reliable results
Our mechanical service follows a systematic approach ensuring quality and safety:
1. Assessment and planning
Review of maintenance history, CMS data analysis, visual inspection, scope definition and parts procurement
2. Preparation and isolation
Safety briefing, LOTO procedures, component access preparation, tooling and lifting equipment setup
3. Disassembly and inspection
Careful component removal, detailed inspection of removed parts, documentation of findings, mating surface preparation
4. Repair or replacement
Component repair where feasible, new part installation per OEM specification, correct torque application, alignment verification
5. Testing and documentation
Functional testing, operational verification, CMS baseline measurement, complete service documentation
GWO-certified team for safe working at height
All mechanical service is performed by personnel holding:
• GWO Certifications
BST (Basic Safety Training), BTT (Basic Technical Training), ART (Advanced Rescue Training) – complete package for wind turbine work
• Mechanical Qualifications
Specialist training in rotating equipment, precision assembly and drivetrain systems
• OEM Training
Manufacturer-specific training including Vestas certified gearbox courses
• Lifting and Rigging
Certified for nacelle crane operations, heavy component handling and working at height
• Hydraulic Systems
Trained in hydraulic system diagnostics, repair and safety procedures
Need mechanical service for your turbines?
Contact us to discuss your mechanical service requirements. We offer rapid response for urgent repairs and flexible scheduling for planned maintenance across Central and Western Europe.