SERVICE BULLETIN REVISION NOTICE

ENGINE — SEAL, 13TH, 14TH, AND 15TH STAGE, HIGH PRESSURE COMPRESSOR (HPC)

— REPLACEMENT OF, AND INTRODUCTION OF A NEW SHOT PEEN SPECIFICATION, TO

IMPROVE REAR DRUM ROTOR DURABILITY

Turbojet Engine Service Bulletin No. PW4G-100-72-240 Revision No. 1 dated June 12, 2012.

Revision History

Original Issue December 2, 2011

Revision 1 dated June 12, 2012

Reason for the Revision

To correct a shotpeen area in Figure 8 and Figure 10 from “shotpeen including break edge” to

“no shotpeen including break edge”.

To correct a shotpeen dimension in Figure 9.

To add arrowheads to four lines in Figure 11.

Effect of Revision on Prior Compliance

None.

This is a Complete Revision (Not Applicable to the SGML version)

The contents are in accordance with the list of effective pages. All pages have the current revision

number. Technical changes are marked with black bars.

MODEL APPLICATION

PW4164, PW4168, PW4168A

BULLETIN ISSUE SEQUENCE

PW4G-100 Series 72-240

Page Revision No. Date

1 thru 17 1 June 12/12

A copy of this Revision Notice and any future revision notices must be filed as a permanent

record with your copy of the subject bulletin.

P&W Distribution Code

2639 PW4G-100-72-240

Page 1 of 1

Published in United States of America

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
SERVICE BULLETIN

ENGINE — SEAL, 13TH, 14TH, AND 15TH STAGE, HIGH PRESSURE COMPRESSOR (HPC)

— REPLACEMENT OF, AND INTRODUCTION OF A NEW SHOT PEEN SPECIFICATION,

TO IMPROVE REAR DRUM ROTOR DURABILITY

MODEL APPLICATION

PW4164, PW4168, PW4168A

BULLETIN ISSUE SEQUENCE

PW4G-100 Series 72-240

ATA NUMBER

72-35-00

UTC/P&W PROPRIETARY INFORMATION

This document is the property of United Technologies Corporation — Pratt & Whitney (UTC/P&W). You may not possess,

use, copy or disclose this document or any information in it, for any purpose, including without limitation to design,

manufacture, or repair parts, or obtain FAA or other government approval to do so, without UTC/P&W’s express written

permission. Neither receipt nor possession of this document alone, from any source, constitutes such permission.

Possession, use, copying or disclosure by anyone without UTC/P&W’s express written permission is not authorized

and may result in criminal and/or civil liability.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).

Compliance Category

6

P&W Distribution Code

2639

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REVISION NO. 1 - June 12/12 Page 1 of 17

Published in United States of America
Summary

The purpose of this Service Bulletin is to replace the High Pressure Compressor (HPC) 13th, 14th

and 15th stage HPC seals and to introduce a new shot peen specification. Cracks are found in the

loading and locking slots of the HPC rear drum rotor assembly. The root cause of these cracks is

Thermal Mechanical Fatigue (TMF). The new seals and shot peen specification were introduced in

the Advantage70TM HPC rear drum rotor assembly and will reduce the causes of TMF.

Planning Information

Effectivity Data

Engine Models Applicable

PW4164, PW4168, PW4168A

Engine Serial Nos. P733301 thru P733692*

* This estimate of engine serial numbers will be revised, if necessary, when parts are

installed in engines at Pratt & Whitney.

NOTE: The engine serial number effectivity data and its related engine model

identification contained in this Service Bulletin are taken from the records of

part(s) incorporation during initial manufacture.

After initial engine manufacture, but before final delivery, P&W may change

part(s) in the engine or change the model identification of the engine. Such

action is recorded on FAA337 forms.

To find Service Bulletin PW4G-100-72-240 models that are applicable, the

owner/operator of the engine must compare the Service Bulletin List supplied

with the engine as sent from P&W and the List of Changes incorporated at the

Airframer from FAA337 forms to the Service Bulletin PW4G-100-240 Effectivity

section.

Concurrent Requirements

There are no concurrent requirements.

Reason

1. Problem: More than 200 HPC rear drum rotor assemblies from PW4000-94 and

PW4000-100 engine models developed cracks in the blade loading and locking slots.

2. Cause: The root cause is determined to be TMF. The TMF cracks are the result

of thermal gradients and related high stresses in the rear of the HPC section. The

high thermal gradients are attributed to seals that allow leakage of hot gases. High

stresses are attributed to shot peening. Shot peening adds a residual compressive

stress which protects against low cycle fatigue conditions, however shot peening can

be a detriment and initiate TMF.

3. Solution: Provide the Advantage70TM HPC rear drum rotor assembly 13th, 14th and

15th stage seals and introduce a new shot peen procedure. The new seals reduce

gas leakage and the associated thermal gradient which contributes to TMF. The new

shot peen procedure reduces the compressive stress in the rear drum rotor assembly

loading and locking slot areas.These improvements will reduce the causes of TMF.

Description

Replace the 13th, 14th and 15th stage seals. Shot peen to the new specification.

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REVISION NO. 1 - June 12/12 Page 2

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
Compliance

Category 6

Do when the subassembly (i.e. modules, accessories, components, build groups) is

disassembled sufficiently to give access to the changed part and to all changed spare parts.

Approval Data

The part number changes and/or part changes specified in the Material Information section

and Accomplishment Instructions of this Service Bulletin agree with the applicable Federal

Aviation Regulations and are FAA-Approved for the engine model(s) given.

Manpower

No more man-hours are necessary when done at complete disassembly/assembly.

Weight Data

No Change.

Electrical Load Data

Not Applicable.

Software Accomplishment Summary

Not Applicable.

References

1. Turbojet Engine Standard Practices Manual, Part No. 585005.

2. PW4164, PW4168, PW4168A, PW4170 Turbofan Engines, Illustrated Parts Catalog,

Part No. 51A343.

3. PW4164, PW4164-1D, PW4164C, PW4164C-1D, PW4164C/B, PW4164C/B-1D, PW4168,

PW4168A, PW4168A-1D, PW4170 Turbofan Engines, Engine Manual, Part No. 51A342.

4. PW4000 Series Turbofan Engines, Engine Cleaning, Inspection And Repair (CIR) Manual,

Part No. 51A357.

5. Service Bulletin No. PW4G-100-72-8; Engine — Blades, 14th And 15th Stage High

Pressure Compressor (HPC) — Modification To Provide Improved Platform Clearance And

Blade Locking. Issue Sequence 72-8, PW4G-100 Series.

NOTE: Reference 5 is shown to help find configurations in relation to this bulletin.

Publications Changed

PW4164, PW4168, PW4168A Turbofan Engines, Illustrated Parts Catalog, Part No.

51A343.

72-35-00, Figures 7, 8, and 9

PW4164, PW4168, PW4168A Turbofan Engines, Engine Manual, Part No. 51A342.

72-35-01

PW4000 Series Turbofan Engines, Engine Cleaning, Inspection And Repair (CIR) Manual,

Part No. 51A357.

72-35-00

72-35-10

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UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
Interchangeability

Old and new parts are interchangeable in full sets by stage.

(When any stage of the HPC rear drum rotor assembly is debladed, use the new seal).

Information in the Appendix

Alternate Accomplishment Instructions (No)

Progression Charts (Yes)

Added Data (Yes)

Revision to Table of Limits (No)

Inspection Procedures (No)

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REVISION NO. 1 - June 12/12 Page 4

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
Material Information

Material — Cost and Availability

1. Part prices were not available at the time of Service Bulletin publication. Contact Pratt &

Whitney Spares Management & Logistics for firm quotations.

2. There is no kit provided to do this Service Bulletin.

3. Part availability information is provided in material data Instructions — Disposition.

Industry Support Program

Not Applicable.

The material data that follows is for each engine.

NOTE: It is possible to use the Chapter/Section and Figure/Item reference number

shown below the old part number to find the part in the Illustrated Parts Catalog.

Because there are many different configurations used, it is frequently necessary

to show more than one group of parts. When this occurs, parts that are

interchangeable are shown line-by-line only, unless this is shown differently.

CAUTION: THE FOLLOWING MATERIAL DATA TABLE(S) ARE ORGANIZED BY

ILLUSTRATED PARTS CATALOG. ALL PARTS IN THE TABLE(S) MAY OR

MAY NOT BE APPLICABLE TO ALL THE ENGINE MODELS SHOWN

IN THE TABLE HEADING. YOU MUST REFER TO THE APPROPRIATE

ILLUSTRATED PARTS CATALOG FOR ENGINE MODEL APPLICABILITY

USING THE OLD PART NUMBER (PN) AND CATALOG SEQUENCE

NUMBER. FAILURE TO INSTALL THE PART(S) IN THE CORRECT

ENGINE MODEL MAY RESULT IN A CONFIGURATION THAT IS NOT FAA

APPROVED.

The material data that follows is for each engine.

For PW4164, PW4168, PW4168A Engines:

New PN Qty Estimate of Unit

Price ($)

Keyword Old PN Instructions —

Disposition

50S158 2 * SEAL — HPC,

13STG

50H935

(72-35-00-7-1 A)

(2)(A)(C2)

6 SEAL — HPC,

14STG

55H587

(72-35-00-8-2)

(C2)

50S159 2 * SEAL — HPC,

14STG

(2)(A)

AR SEAL — HPC,

15STG

55H588

(72-35-00-9-15)

(C2)

AR SEAL — HPC,

15STG

54H335-001

(72-35-00-9-10AA)

(N)

50S160 2 * SEAL — HPC,

15STG

(2)(A)

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REVISION NO. 1 - June 12/12 Page 5

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
Modification and Spares Information

Estimated part prices are provided when they are available at time of publication. The

Estimate of Unit Price is only for planning purposes and does not constitute a firm

quotation. An asterisk (*) is shown where part pricing information was unavailable. In either

case, contact Pratt & Whitney Spares Management & Logistics for firm quotations.

Parts Modification Conditions

(2) The new part is a replacement part only, and cannot be obtained by modification

of the old part.

Spare Parts Availability

(A) The new part is available.

(C2) The old part will continue to be supplied for use in other engine models.

(N) The old part is not available.

Vendor Services or Special Components/Materials

Not Applicable.

Material Data for Each Spare Engine

The material for each spare engine is as stated in the preceding material information

section.

Reidentified Parts

Not Applicable.

Necessary Tools

No more Support Equipment is necessary.

Other Material Information Data

Not Applicable.

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November 15/11

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REVISION NO. 1 - June 12/12 Page 6

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
Accomplishment Instructions

1. Replace the seals as follows.

A. Replace 13th Stage Seals, PN 50H935 with PN 50S158. See Figure 1.

B. Replace 14th Stage Seals, PN 55H587 with PN 50S159. See Figure 2.

C. Replace 15th Stage Seals, PN 55H588 or PN 54H335-001 with PN 50S160. See

Figure 3.

2. If it is necessary to shot peen the drum rotor as specified in Reference 4, CIR Manual,

Chapter/Section 72-35-10, Repair-04, Repair-13 and Repair-14, then DO NOT shot peen

the loading and locking slots as shown in the Appendix.

3. Assemble the 13th stage, 14th stage, 15th stage seals as follows.

NOTE: Reference 3, Engine Manual, Revision 69, dated May 15, 2012 is scheduled to

incorporate the new assembly procedure related to this Service Bulletin and will

take precedence over the Service Bulletin.

A. Assemble the new 15th stage seals as specified in Reference 3, Engine Manual,

Chapter/Section 72-35-01, Assembly-04, Paragraph 5 (applicable only to the seal

assembly instructions of the EM procedure).

B. Assemble the new 14th stage seals as specified in Reference 3, Engine Manual,

Chapter/Section 72-35-01, Assembly-05, Paragraph 4 (applicable only to the seal

assembly instructions of the EM procedure).

C. Assemble the new 13th stage new seals as specified in Reference 3, Engine Manual,

Chapter/Section 72-35-01, Assembly-06, Paragraph 4 (applicable only to the seal

assembly instructions of the EM procedure).

NOTE: Assembly of the new seals on Drum Rotor Assembly, PN 58H236-01 or

PN 56H013-001 or PN 54H803-002 is the same as on Drum Rotor Assembly,

PN 50S813-01.

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REVISION NO. 1 - June 12/12 Page 7

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
LOCATION OF THE 13TH STAGE SEAL

72-35-00

FIGURE 1

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November 15/11

PW4G-100-72-240

REVISION NO. 1 - June 12/12 Page 8

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
LOCATION OF THE 14TH STAGE SEAL

72-35-00

FIGURE 2

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REVISION NO. 1 - June 12/12 Page 9

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
LOCATION OF THE 15TH STAGE SEAL

72-35-00

FIGURE 3

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REVISION NO. 1 - June 12/12 Page 10

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
Appendix

Parts Progression To Show the Changed Part in Relation to Other Parts

13TH, 14TH AND 15TH STAGE SEALS

CHART A

Added Data

Internal Reference Information

Revision No.

Reference

Document

Origination

Original

EC09KA021

EC09KA021G

EC09KA021X

EC09KA021Y

EC10KK044T

KVG/MJS

1 EC10KK044U KVG/MJS

Number values shown in parentheses adjacent to U.S. values are International System of

units (SI) equivalents.

HPC Rear Drum Rotor Loading And Locking Slot — New Shot Peen Specifications

NOTE: Reference 4, CIR Manual, Revision 72, dated September 15, 2012 is scheduled to

incorporate the new shot peen specifications related to this Service Bulletin and will

take precedence over the Service Bulletin.

1. Whenever it is necessary to shot peen the HPC rear drum rotor as specified in Reference 4,

CIR, Chapter/Section 72-35-10, Repair-04, -13, and -14 do the repair except DO NOT shot

peen the loading and locking slot locations as shown in Figures 4 thru 12.

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REVISION NO. 1 - June 12/12 Page 11

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
13TH STAGE LOAD AND LOCK SLOT LOCATION

FIGURE 4

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REVISION NO. 1 - June 12/12 Page 12

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
14TH STAGE LOAD AND LOCK SLOT LOCATION

FIGURE 5

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REVISION NO. 1 - June 12/12 Page 13

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
15TH STAGE LOAD AND LOCK SLOT LOCATION

FIGURE 6

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REVISION NO. 1 - June 12/12 Page 14

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
REAR DRUM LOAD AND LOCK SLOT LOCATIONS

FIGURE 7

14TH AND 15TH STAGE LOAD SLOT PEENING SPECIFICATION

FIGURE 8

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REVISION NO. 1 - June 12/12 Page 15

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
13TH, 14TH AND 15TH STAGE LOAD SLOT PEENING SPECIFICATION

FIGURE 9

13TH STAGE LOAD SLOT PEENING SPECIFICATION

FIGURE 10

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REVISION NO. 1 - June 12/12 Page 16

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).
13TH, 14TH AND 15TH STAGE LOCK SLOT PEENING SPECIFICATION

FIGURE 11

14TH AND 15TH STAGE LOCK SLOT PEENING SPECIFICATION

FIGURE 12

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PW4G-100-72-240

REVISION NO. 1 - June 12/12 Page 17

UTC/P&W PROPRIETARY INFORMATION

Subject to the restrictions on the cover or first page.

Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3).