# SER VICE BULLETIN REVISION NOTICE

ENGINE

— SEAL, 13TH, 14TH, AND 15TH ST AGE, HIGH PRESSURE COMPRESSOR (HPC)

— REPLACEMENT OF, AND INTRODUCTION OF A NEW SHOT PEEN SPECIFICA TION, TO IMPROVE REAR DRUM ROTOR DURABILITY Turbojet Engine Service Bulletin No. PW4G-100-72-240 Revision No. 1 dated June 12, 2012. Rev i s i o n H i sto ry Original Issue December 2, 201 1 Revision 1 dated June 12, 2012 Re aso n f o r th e Rev i s i o n T o correct a shotpeen area in Figure 8 and Figure 10 from “shotpeen including break edge” to “no shotpeen including break edge”. T o correct a shotpeen dimension in Figure 9. T o add arrowheads to four lines in Figure 1 1. Ef fe ct of Rev i s i o n o n P ri o r Co m p l i a n ce None. T h i s i s a Co m p l ete Rev i s i o n ( N ot Ap p l i ca b l e to t h e S G M L ve rs i o n ) The contents are in accordance with the list of ef fective pages. All pages have the current revision number

. T echnical changes are marked with black bars. M O D E L A P P L I CA T I O N PW4164, PW4168, PW4168A B U L L E T I N I S S U E S E Q U E N C E PW4G-100 Series 72-240

P a g e Rev i s i o n N o

. D ate 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 D i stri b u ti o n Cod e 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).

# SER VICE BULLETIN

ENGINE

— SEAL, 13TH, 14TH, AND 15TH ST AGE, HIGH PRESSURE COMPRESSOR (HPC)

— REPLACEMENT OF, AND INTRODUCTION OF A NEW SHOT PEEN SPECIFICA TION, TO IMPROVE REAR DRUM ROTOR DURABILITY
M O D E L A P P L I CA T I O N PW4164, PW4168, PW4168A
B U L L E T I N I S S U E S E Q U E N C E PW4G-100 Series 72-240
A T A N U M B E R 72-35-00

U TC/ P &W P RO P R I E T A R Y I N F O R M A T I O N This document is the property of United T echnologies Corporation

— Pratt & Whitney (UTC/P&W). Y ou 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 F AA 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). Co m p l i a n ce C ateg o ry 6 P &W D i stri b u ti o n Cod e 2639 

## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 1 of 17 Published in United States of AmericaS u m m a ry 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

. P l a n n i n g I n f o rm ati o n Ef fe cti v i ty D ata E n g i n e M od e l s Ap p l i ca b l e 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

. N OT E : The engine serial number ef fectivity 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 F AA337 forms. T o 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 F AA337 forms to the Service Bulletin PW4G-100-240 Ef fectivity section. Co n cu rre n t Re q u i re m e n ts There are no concurrent requirements. Re a so n 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

. D es c ri pt i o n Replace the 13th, 14th and 15th stage seals. Shot peen to the new specification.


## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 2 UTC/P&W PROPRIET AR Y INFORMA TION 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).Co m p l i a n ce Category 6 Do when the subassembly (i.e. modules, accessories, components, build groups) is disassembled suf ficiently to give access to the changed part and to all changed spare parts. Ap p rova l D ata 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 A viation Regulations and are F AA-Approved for the engine model(s) given. M a n p owe r No more man-hours are necessary when done at complete disassembly/assembly

. We i g h t D ata No Change. E l e ctri ca l Lo a d D ata Not Applicable. S of twa re Acco m p l i s h m e n t S u m m a ry Not Applicable. Refe re n ces 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 T o Provide Improved Platform Clearance And Blade Locking. Issue Sequence 72-8, PW4G-100 Series. N OT E : Reference 5 is shown to help find configurations in relation to this bulletin. P u b l i cati o n s C h a n g e d 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



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 3 UTC/P&W PROPRIET AR Y INFORMA TION 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).I n te rc h a n g e a b i l i ty 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). I n f o rm at i o n i n th e Ap p e n d i x Alternate Accomplishment Instructions (No) Progression Charts (Y es) Added Data (Y es) Revision to T able of Limits (No) Inspection Procedures (No)



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 4 UTC/P&W PROPRIET AR Y INFORMA TION 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).M ate ri a l I n f o rm ati o n M ate ri a l

— Cost a n d A va i l a b i l i ty 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. I n d u stry S u p p o rt P rog ra m Not Applicable. T h e m ate ri a l d ata th at f o l l ows i s f o r e a c h e n g i n e

. N OT E : 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 dif ferent 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 dif ferently

. CA U T I O N : THE FOLLOWING MA TERIAL DA T A T ABLE(S) ARE ORGANIZED BY ILLUSTRA TED P ARTS CA T ALOG. ALL P ARTS IN THE T ABLE(S) MA Y OR MA Y NOT BE APPLICABLE TO ALL THE ENGINE MODELS SHOWN IN THE T ABLE HEADING. YOU MUST REFER TO THE APPROPRIA TE ILLUSTRA TED P ARTS CA T ALOG FOR ENGINE MODEL APPLICABILITY USING THE OLD P ART NUMBER (PN) AND CA T ALOG SEQUENCE NUMBER. F AILURE TO INST ALL THE P ART(S) IN THE CORRECT ENGINE MODEL MA Y RESUL T IN A CONFIGURA TION THA T IS NOT F AA APPROVED. T h e m ate ri a l d ata th at f o l l ows i s f o r e a c h e n g i n e

. F o r PW4 1 64 , PW4 1 6 8 , PW4 1 6 8A E n g i n es : 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)



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 5 UTC/P&W PROPRIET AR Y INFORMA TION 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).M od i fi cat i o n a n d S p a res I n f o rm ati o n 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 A vailability (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. V endor Services or Special Components/Materials Not Applicable. M ate ri a l D ata f o r E a c h S p a re E n g i n e The material for each spare engine is as stated in the preceding material information section. Re i d e n t i fi e d P a rts Not Applicable. N e cess a ry T oo l s No more Support Equipment is necessary

. Oth e r M ate ri a l I n f o rm ati o n D ata Not Applicable.



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 6 UTC/P&W PROPRIET AR Y INFORMA TION 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).Acco m p l i s h m e n t I n stru cti o n s 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. N OT E : 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). N OT E : 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.



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 7 UTC/P&W PROPRIET AR Y INFORMA TION 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).LOCA TION OF THE 13TH ST AGE SEAL 72-35-00 FIGURE 1


## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 8 UTC/P&W PROPRIET AR Y INFORMA TION 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).LOCA TION OF THE 14TH ST AGE SEAL 72-35-00 FIGURE 2


## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 9 UTC/P&W PROPRIET AR Y INFORMA TION 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).LOCA TION OF THE 15TH ST AGE SEAL 72-35-00 FIGURE 3


## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 10 UTC/P&W PROPRIET AR Y INFORMA TION 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).Ap p e n d i x P a rts P rog ress i o n T o S h ow th e C h a n g e d P a rt i n Re l ati o n to Ot h e r P a rts

13TH, 14TH AND 15TH ST AGE SEALS CHART A Ad d e d D ata I n te rn a l Refe re n ce I n f o rm at i o n
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. H P C Re a r D ru m Roto r Loa d i n g An d Lo c ki n g S l ot

— N ew S h ot P e e n S p e c i fi cati o n s N OT E : 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.



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 1 1 UTC/P&W PROPRIET AR Y INFORMA TION 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 ST AGE LOAD AND LOCK SLOT LOCA TION FIGURE 4



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 12 UTC/P&W PROPRIET AR Y INFORMA TION 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 ST AGE LOAD AND LOCK SLOT LOCA TION FIGURE 5



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 13 UTC/P&W PROPRIET AR Y INFORMA TION 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 ST AGE LOAD AND LOCK SLOT LOCA TION FIGURE 6



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 14 UTC/P&W PROPRIET AR Y INFORMA TION 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 LOCA TIONS FIGURE 7

14TH AND 15TH ST AGE LOAD SLOT PEENING SPECIFICA TION FIGURE 8



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 15 UTC/P&W PROPRIET AR Y INFORMA TION 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 ST AGE LOAD SLOT PEENING SPECIFICA TION FIGURE 9

13TH ST AGE LOAD SLOT PEENING SPECIFICA TION FIGURE 10



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 16 UTC/P&W PROPRIET AR Y INFORMA TION 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 ST AGE LOCK SLOT PEENING SPECIFICA TION FIGURE 1 1

14TH AND 15TH ST AGE LOCK SLOT PEENING SPECIFICA TION FIGURE 12



## l November 15/1 1 

# PW4G-100-72-240 REVISION NO. 1

- June 12/12 Page 17 UTC/P&W PROPRIET AR Y INFORMA TION 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).