10/02/2026
We invite you to look inside of our kitchen.
For those of you who are familiar with the art of performing large corrective repairs in wind turbines, you're probably well aware of how difficult it can be to stab a main shaft into a gearbox, or to gently slide a gearbox onto a main shaft.
The tolerances are far less than 1 millimetre, and stakes are high. If the connection is not mated perfectly, the main shaft can easily get jammed up inside the hollow shaft, causing damage. And if things go really badly, the connection can get seized up, requiring high-power hydraulics to separate the equipment again.
It's no wonder that this is a difficult thing to do. Most of the time, these operations are performed with traditional cranes on the ground. This means that equipment is hanging on a crane hook, being controlled by a large machine and an operator located hundreds of feet below. Every movement requires a command by radio down to the crane operator, who is completely blind to the operation inside the nacelle.
It requires high skill by an operator to shift the crane hook within millimetre precision, considering that the long crane boom is deflecting and the load may be swaying gently in the breeze. What makes things even more difficult is that the main shaft must be inserted into the gearbox at a slight angle, usually around 5 degrees from the horizontal. This all must be done using the hoisting, slewing, and booming functions of the crane. None of these functions align perfectly with the connection being installed.
At LiftWerx, our process makes this process far easier. We use cranes which are designed exactly for this purpose. Our RotorHook boom angle is parallel with the main shaft, and the linear trolley function allows us to slide the main shaft directly into or out of the gearbox, at the precise angle, and with no boom deflection. And the best part? The operator on the left, who operates the crane's remote controller while performing the lift, has full view of the connection, and stands within arms length.
With beautifully-designed technology like this, it's no wonder that we're able to perform hundreds of large corrective repairs each year, with world-class safety, quality, and efficiency.
TCGM