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This page covers gearbox lubricant requirements, oil-change procedures, level checks, maintenance tasks, and related condition findings.

Overview

The current site change record says the gearbox oil change from Proseware PWG 320 to Proseware PWG 220 applies to WTG-01 through WTG-12, and the service bulletin says the affected manual section is the lubrication section of LWS-MM-GBX-32 Rev. D.12345 For converted gearboxes, the procedure uses a 60 L PWG 220 flush, a 410 L PWG 220 final fill through a 10 micron filter cart, a GBX_TMIN_START setting of 5 °C, PWG 220 labelling, and a requirement that residual PWG 320 remain below 5 % of oil volume.6789 Routine gearbox lubrication maintenance includes oil sampling and laboratory analysis every 6 months, oil filter element replacement every 12 months, and gearbox oil changes every 5 years or on condition.101112 WTG-07 has a current gearbox condition issue: its oil analysis was ALERT, ferrous wear and particle count were above alert limits, and the related incident report says vibration remains above the alarm level until the bearing is replaced.1314

Applicability and document control

  • SB-LWS-2025-07 is categorized as recommended but mandatory to keep the gearbox warranty, and it applies to LT-32 turbines delivered in CCV configuration with Fabrikam FGT-3200 gearboxes and to LT-32 standard turbines at sites where ambient temperature regularly falls below -20 °C.1
  • For affected turbines, compliance with SB-LWS-2025-07 is required at the next scheduled oil change and no later than 2025-12-31.1
  • MOC-2025-012 scopes the technical lubricant change to WTG-01 through WTG-12 and says Litware support confirmed that SB-LWS-2025-07 applies to all 12 CCV turbines at Quellmoor Ridge.2345
  • SOP-GBX-010 Rev. B is effective from 2025-08-25, applies to WTG-01 through WTG-12 with Litware LT-32 CCV turbines and Fabrikam FGT-3200 gearboxes, and implements MOC-2025-012 and SB-LWS-2025-07 Rev. A.151617
  • The maintenance manual says Litware Wind Systems publishes gearbox chapter changes as service bulletins and that the bulletin register must be checked before planning gearbox work.18

Lubricant specification and quantities

  • The service bulletin changes affected turbines from Proseware PWG 320 to Proseware PWG 220 and from ISO VG 320 to ISO VG 220, while the total oil volume remains 410 L.1
  • The Rev. D maintenance manual still lists Proseware PWG 320, ISO VG 320, with synthetic PAO base oil as the approved gear oil and states that the total oil volume is 410 L, made up of 330 L in the gearbox sump and 80 L in the cooling and filter circuit.19
  • Each SOP Rev. B oil change requires 470 L of Proseware PWG 220, consisting of 60 L for flushing and 410 L for filling, plus one FGT-P-11872 oil filter element.2021
  • The maintenance manual says lubricants of different brands or viscosity grades must not be mixed, and SOP Rev. B says a converted gearbox must never be topped up with PWG 320.199
  • The spare-parts snapshot lists PWS-320-D208 as Proseware PWG 320 gear oil with a do-not-use note tied to MOC-2025-012.22

Oil-change procedure and controls

  • Before the oil circuit is opened, SOP Rev. B requires a permit to work, at least two technicians, no lone working in the nacelle, and isolation under SOP-LOTO-001.2324
  • SOP Rev. B says the job must not start if the 10-minute mean wind speed exceeds 15 m/s, and hot-oil controls require chemical gloves, a face shield, long sleeves, and draining only between 40 and 60 °C.2526
  • Before draining, the turbine is stopped, lockout/tagout is applied with the rotor locked and drivetrain isolated, oil temperature is checked, and oil is drained between 40 and 60 °C.2728
  • The procedure takes a used-oil sample at the sampling valve, drains the gearbox sump and cooling and filter circuit into waste containers, and gives the approximate drained volume as 410 L.2930
  • During the oil change, the FGT-P-11872 filter element is replaced, the filter housing cover screws are tightened to 85 Nm, and the drain plug is refitted with a new seal and tightened to 280 Nm.3132
  • After the flush and final fill, SOP Rev. B requires running the electric oil pump for 15 minutes, checking all connections for leaks, and checking the oil level at the sight glass after 20 minutes of standstill.673334
  • SOP Rev. B requires a reference oil sample after 24 hours of operation, recording quantities and batch numbers in the work order, sending the completion form to Litware Wind Systems within 30 days, and storing waste oil in the bunded store for licensed-carrier collection.353637

Oil level checks and top-up

  • SOP Rev. B says the oil level is checked at the sight glass after 20 minutes of standstill according to SPL-012 and topped up only with PWG 220.34
  • SPL-012 says the gearbox oil level is read at the generator-side sight glass and must be between MIN and MAX.38
  • SPL-012 says top-up is only permitted with PWG 220 through the 10 micron filter cart and that PWG 320 must not be used.38
  • SPL-012 says that if the level is below MIN, the turbine must not be restarted and the condition is reported to the O&M Supervisor because of the risk of alarm A2130.39

Temperatures, filters, and alarms

  • The manual gives normal oil sump temperature in operation as 50 to 65 °C and states that warning A2101 is set at 75 °C and trip A2102 is set at 82 °C.19
  • SB-LWS-2025-07 says the A2101 and A2102 temperature thresholds remain 75 °C and 82 °C after the viscosity-grade change.1
  • The manual says the oil passes through a 10 micron inline filter and an air/oil cooler with an electric fan, and that the thermostatic valve sends oil through the cooler above 45 °C.40
  • The manual says the FGT-P-11872 filter element must be replaced every 12 months or at alarm A2140, and that A2140 is gearbox oil filter differential pressure high at 2.5 bar.1941
  • The manual says A2120 is gearbox oil pressure low at 0.8 bar and can be caused by cold oil at start-up, pump fault, or a blocked filter.41

Oil analysis and condition monitoring

  • The maintenance manual gives oil analysis alert and alarm limits for iron, copper, silicon, water, viscosity change, PQ index, and cleanliness ISO 4406.42
  • For output-stage HSS bearings, the maintenance manual gives velocity RMS limits of 3.5 mm/s alert and 4.5 mm/s alarm.42
  • WTG-07 oil sample TR-26-11873 used Proseware PWG 220, ISO VG 220, and was sampled on 2026-06-10 from the sampling valve with oil at operating temperature.13
  • The WTG-07 oil report says viscosity and water content were normal for PWG 220, but iron, PQ index, and particle count were at ALERT status.13
  • The WTG-07 oil report interprets large ferrous particles with normal copper as indicating rolling-element bearing distress rather than gear wear, and recommends reviewing output-stage bearing vibration trends, endoscope inspection of HSS bearings, filter replacement, and resampling within 30 days.13

WTG-07 overheating incident

  • Between 2026-04-09 and 2026-06-21, WTG-07 logged 27 A2101 warnings at 75 °C and two A2102 trips at 82 °C, while no other turbine logged an A2101 warning in that period.43
  • The WTG-07 HSS bearing vibration on the generator side rose from 2.1 mm/s RMS to 5.2 mm/s RMS and exceeded the 4.5 mm/s alarm level.44
  • The incident report says the oil overheated because the oil cooler did not reject enough heat at high load, the cooler fan ran at reduced speed, and the radiator fins were about 40 % blocked by insects and pollen.4546
  • The incident report identifies the root cause as missing preventive maintenance of the oil cooler, allowing fan motor bearing failure and radiator fouling to reduce cooling capacity.47
  • Completed corrective actions on 2026-06-24 were replacing oil cooler fan motor LWS-P-30418 and cleaning the oil cooler radiator, and verification reports no A2101 warning on WTG-07 since 2026-06-24.484914
  • Replacement of WTG-07 generator-side HSS bearing FGT-P-22328 is waiting for parts, and the 8D remains open until the bearing replacement and an oil sample 500 operating hours after the bearing replacement.5051

Maintenance plan and spares

  • Maintenance Plan 2026 issue 2 added task MP-GBX-07 for oil cooler radiator cleaning and fan current check on all turbines after INC-2026-006.5253
  • The plan schedules gearbox oil sampling and laboratory analysis every 6 months, oil filter element replacement every 12 months, gearbox oil changes every 5 years or on condition, and monthly vibration trend review.10111254
  • For WTG-07, the maintenance plan records oil analysis report TR-OA-2026-0614 with PWG 220 oil, Fe 64 ppm, PQ index 112, ALERT condition, and next sample due 2026-07-10 with resampling within 30 days.55
  • The spare-parts snapshot shows generator-side HSS bearing FGT-P-22328 as a critical item below minimum stock, with 0 pieces on hand, a minimum of 1 piece, 2 pieces on order under PO-76994, and expected delivery on 2026-09-25.5657
  • The spare-parts snapshot shows oil cooler fan motor LWS-P-30418 as a critical item below minimum stock, with 1 piece on hand, a minimum of 2 pieces, and 2 pieces on order under PO-77102 for expected delivery on 2026-08-14.5658

Conversion completion status

  • The work-orders export records a completed high-priority modification campaign for gearbox oil conversion from PWG 320 to PWG 220 with a 60 L flush for WTG-01 through WTG-12 under MOC-2025-012.596061626364656667686970
  • The WTG-09 gearbox oil conversion work order was deferred because the access road was closed by snow on 2025-11-24 and was completed on 2026-01-20.67

Contradictions

Resolution policy: When two current sources disagree, the source with the higher document-type authority wins (environmental permit 10; service bulletin and grid instruction 9; maintenance manual and management of change 8; procedures, laboratory and inspection reports 7). With equal authority the more recent source wins. A service bulletin that amends a manual section for some turbines is shown next to the manual value, with the turbines it applies to.

Superseded information

Sources consulted

Sources

Footnotes

  1. SB-LWS-2025-07 Rev. A - Gearbox oil viscosity grade change for LT-32 CCV turbines — p. 1 · ✓ quote verified ↩ ↩2 ↩3 ↩4 ↩5

  2. MOC-2025-012 - Gearbox Oil Grade Change to PWG 220 — table 1, row 3 · table ↩ ↩2

  3. MOC-2025-012 - Gearbox Oil Grade Change to PWG 220 — table 1, row 4 · table ↩ ↩2

  4. MOC-2025-012 - Gearbox Oil Grade Change to PWG 220 — table 1, row 5 · table ↩ ↩2

  5. MOC-2025-012 - Gearbox Oil Grade Change to PWG 220 — ¶ 4 · ✓ quote verified ↩ ↩2

  6. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 34 · ✓ quote verified ↩ ↩2

  7. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 35 · ✓ quote verified ↩ ↩2 ↩3

  8. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 38 · ✓ quote verified ↩ ↩2

  9. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 42 · ✓ quote verified ↩ ↩2

  10. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Tasks", row 2 · table ↩ ↩2

  11. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Tasks", row 3 · table ↩ ↩2

  12. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Tasks", row 4 · table ↩ ↩2

  13. Oil analysis report TR-OA-2026-0614 - WTG-07 gearbox oil — p. 1 · ✓ quote verified ↩ ↩2 ↩3 ↩4

  14. 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10) — ¶ 24 · ✓ quote verified ↩ ↩2

  15. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 2 · ✓ quote verified ↩ ↩2

  16. SOP-GBX-010 Rev. B - Gearbox oil change — table 1, row 7 · table ↩

  17. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 3 · ✓ quote verified ↩ ↩2

  18. LWS-MM-GBX-32 Rev. D — LT-32 Maintenance Manual Chapter 4 Gearbox Excerpt — p. 1 · ✓ quote verified ↩

  19. LWS-MM-GBX-32 Rev. D — LT-32 Maintenance Manual Chapter 4 Gearbox Excerpt — p. 3 · ✓ quote verified ↩ ↩2 ↩3 ↩4

  20. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 22 · ✓ quote verified ↩ ↩2 ↩3

  21. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 23 · ✓ quote verified ↩ ↩2

  22. Spare Parts Stock Snapshot 2026-07-21 for Quellmoor Ridge O&M Building — sheet "Stock", row 19 · table ↩

  23. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 16 · ✓ quote verified ↩

  24. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 17 · ✓ quote verified ↩

  25. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 18 · ✓ quote verified ↩

  26. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 19 · ✓ quote verified ↩

  27. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 27 · ✓ quote verified ↩

  28. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 28 · ✓ quote verified ↩

  29. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 29 · ✓ quote verified ↩

  30. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 30 · ✓ quote verified ↩

  31. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 32 · ✓ quote verified ↩

  32. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 33 · ✓ quote verified ↩

  33. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 36 · ✓ quote verified ↩

  34. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 37 · ✓ quote verified ↩ ↩2 ↩3

  35. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 40 · ✓ quote verified ↩

  36. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 41 · ✓ quote verified ↩

  37. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 44 · ✓ quote verified ↩

  38. SPL-012 Gearbox Oil Level Check — slide 2 · ✓ quote verified ↩ ↩2

  39. SPL-012 Gearbox Oil Level Check — slide 3 · ✓ quote verified ↩

  40. LWS-MM-GBX-32 Rev. D — LT-32 Maintenance Manual Chapter 4 Gearbox Excerpt — p. 2 · ✓ quote verified ↩

  41. LWS-MM-GBX-32 Rev. D — LT-32 Maintenance Manual Chapter 4 Gearbox Excerpt — p. 5 · ✓ quote verified ↩ ↩2

  42. LWS-MM-GBX-32 Rev. D — LT-32 Maintenance Manual Chapter 4 Gearbox Excerpt — p. 4 · ✓ quote verified ↩ ↩2

  43. 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10) — ¶ 6 · ✓ quote verified ↩

  44. 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10) — ¶ 7 · ✓ quote verified ↩

  45. 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10) — ¶ 12 · ✓ quote verified ↩

  46. 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10) — ¶ 13 · ✓ quote verified ↩

  47. 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10) — ¶ 17 · ✓ quote verified ↩

  48. 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10) — table 2, row 2 · table ↩

  49. 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10) — table 2, row 3 · table ↩

  50. 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10) — table 2, row 5 · table ↩

  51. 8D report INC-2026-006 - Repeated gearbox oil over-temperature on WTG-07 (revision 2026-07-10) — ¶ 26 · ✓ quote verified ↩

  52. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Revision log", row 3 · table ↩

  53. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Tasks", row 8 · table ↩

  54. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Tasks", row 7 · table ↩

  55. Maintenance Plan 2026, Issue 2 — Quellmoor Ridge Wind Farm — sheet "Oil sampling", row 8 · table ↩

  56. Spare Parts Stock Snapshot 2026-07-21 for Quellmoor Ridge O&M Building — sheet "About", row 3 · table ↩ ↩2 ↩3

  57. Spare Parts Stock Snapshot 2026-07-21 for Quellmoor Ridge O&M Building — sheet "Stock", row 2 · table ↩ ↩2

  58. Spare Parts Stock Snapshot 2026-07-21 for Quellmoor Ridge O&M Building — sheet "Stock", row 9 · table ↩

  59. Work Orders Export through 2026-08-31 — row 2 · table ↩

  60. Work Orders Export through 2026-08-31 — row 3 · table ↩

  61. Work Orders Export through 2026-08-31 — row 4 · table ↩

  62. Work Orders Export through 2026-08-31 — row 5 · table ↩

  63. Work Orders Export through 2026-08-31 — row 6 · table ↩

  64. Work Orders Export through 2026-08-31 — row 7 · table ↩

  65. Work Orders Export through 2026-08-31 — row 8 · table ↩

  66. Work Orders Export through 2026-08-31 — row 9 · table ↩

  67. Work Orders Export through 2026-08-31 — row 10 · table ↩ ↩2

  68. Work Orders Export through 2026-08-31 — row 11 · table ↩

  69. Work Orders Export through 2026-08-31 — row 12 · table ↩

  70. Work Orders Export through 2026-08-31 — row 13 · table ↩

  71. SPL-012 Gearbox Oil Level Check — slide 1 · ✓ quote verified ↩

  72. Fabrikam Supplier Note on PO-76994 HSS Bearings and PWG 220 Follow-up — lines 8–11 · ✓ quote verified ↩ ↩2

  73. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 19 · ✓ quote verified ↩ ↩2

  74. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 31 · ✓ quote verified ↩

  75. SOP-GBX-010 Rev. B - Gearbox oil change — table 2, row 3 · table ↩ ↩2

  76. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 34 · ✓ quote verified ↩

  77. SOP-GBX-010 Rev. B - Gearbox oil change — ¶ 39 · ✓ quote verified ↩

  78. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 20 · ✓ quote verified ↩

  79. SOP-GBX-010 - Gearbox oil change, Revision A — ¶ 2 · ✓ quote verified ↩

  80. SOP-GBX-010 - Gearbox oil change, Revision A — table 1, row 2 · table ↩

  81. SOP-GBX-010 - Gearbox oil change, Revision A — table 1, row 3 · table ↩

  82. SOP-GBX-010 - Gearbox oil change, Revision A — table 1, row 4 · table ↩

  83. SOP-GBX-010 - Gearbox oil change, Revision A — table 2, row 2 · table ↩

Provenance badges✓ quote verified the quoted words were found verbatim in the source texttable values parsed deterministically from the cited table rows