PRATT & WHITNEY CANADA

SERVICE BULLETIN
P&WC S.B. No. 3002R24

BULLETIN INDEX LOCATOR

TURBOPROP ENGINE
ROTOR COMPONENTS - SERVICE LIFE

MODEL APPLICATION
PT6A-38, PT6A-41, PT6A-42, PT6A-42A, PT6A-45A, PT6A-45B, PT6A-45R
Model(s) deleted this revision: PT6A-40, PT6A-41AG

Compliance: Refer to Para. 1.E. in the Service Bulletin

Summary: 1. This service bulletin provides the service life limits for the rotor component parts
which are authorized for use in the above Pratt & Whitney Canada Inc. engine
models, as required by the Canadian Department of Transport regulations.
2. Compliance with the Accomplishment Instructions in Paragraph 3 is necessary to
maintain conformity with the approval type design and the validity of the
airworthiness certification.

Sep 03/1975 PT6A-72-3002

Revision No. 24: Sep 10/2002 Cover Sheet

24-Hour Global Service USA & CANADA........................ 1-800-268-8000 Other .......................................... 1-450-647-8000
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Pratt & Whitney Canada Corp.
1000, Marie-Victorin
Longueuil, Québec, Canada J4G 1A1
Tél. 450-677-9411

10 September 2002

P&WC S.B. No. 3002R24

REVISION TRANSMITTAL SHEET

TURBOPROP ENGINE MODEL PT6A

SUBJECT: Pratt & Whitney Canada Service Bulletin No. PT6A-72-3002, Rev. No. 24, dated Sep
10/2002 (P&WC S.B. No. 3002R24) ROTOR COMPONENTS - SERVICE LIFE

Replace your existing copy of this service bulletin with the attached revised bulletin. Destroy the
superseded copy.

Please retain this Revision Transmittal Sheet with the revised bulletin.

SUMMARY: This revision is issued to:

v Delete PT6A-40 and PT6A-41AG Engine Model as they are obsoleted;

v add a new rear rotor compressor P/N 3053921-01 (Ref. P&WC SB No. 3372);
v correct the PT6A-42A Life items;
v add the PT6A-45R effectivity to P/N 3031945;
v add PT Disks P/N 3058922-01 and P/N 3058923-01 to the PT6A-41 and PT6A-42
Engines (Ref. P&WC SB No. 3403); and
v add an explanation of Accumulated Total Cycle calculation.

EFFECT OF REVISION ON PRIOR ACCOMPLISHMENT:

None.

NOTE: A black bar in the left margin indicates a change in that line of text or figure.

REVISION HISTORY:
Original Issue: Sep 03/1975 Revision No. 5: May 11/1979 Revision No. 10: Feb 09/1982
Revision No. 1: May 27/1977 Revision No. 6: Jan 23/1980 Revision No. 11: Aug 16/1982
Revision No. 2: Aug 15/1977 Revision No. 7: Jun 16/1980 Revision No. 12: Nov 09/1983
Revision No. 3: Jul 13/1978 Revision No. 8: Feb 23/1981 Revision No. 13: Feb 13/1984
Revision No. 4: Jan 10/1979 Revision No. 9: Oct 02/1981 Revision No. 14: May 01/1985
Pratt & Whitney Canada Corp.

Revision No. 15: Oct 14/1986

Revision No. 16: Jun 29/1987
Revision No. 17: Jun 13/1988
Revision No. 18: Jun 28/1989
Revision No. 19: Feb 27/1991
Revision No. 20: Jan 04/1995
Revision No. 21: Nov 07/1995
Revision No. 22: Dec 15/1998
Revision No. 23: Mar 30/1999
Revision No. 24: Sep 10/2002
 PRATT & WHITNEY CANADA

SERVICE BULLETIN
P&WC S.B. No. 3002R24
TURBOPROP ENGINE
ROTOR COMPONENTS - SERVICE LIFE

1. Planning Information

A. Effectivity
PT6A-38, PT6A-41, PT6A-42, PT6A-42A, PT6A-45A, PT6A-45B, PT6A-45R

B. Concurrent Requirements

None.

C. Reason

(1) To provide initial rotor components service life in accordance with D.O.T. regulation.

(2) To provide information covering method of marking.

D. Description

(1) Engine rotating components listed under Paragraph 3.D. (Ref. Tables 1 and 2) are
subject to low-cycle fatigue due to cyclic operation of the engine. As a result, these
parts must be replaced when their respective accumulated total cycle limit is
reached.

(2) Operators must record all flights, starts and accumulated total cycles (which must
be calculated using the formula Ref. Para. 3.F.) in the applicable document for
each component (i.e. logbook, LCF component card, etc.).

(3) The following is additional information for the Accumulated Total Cycle calculation:

v A start is defined as an engine start followed by one or more flights.

v Aircraft operation often includes abbreviated engine cycles. The definition of an
abbreviated cycle is: idle - takeoff - flight - landing - idle. A normal or full cycle
includes the foregoing plus an engine start and shutdown (i.e. abbreviated cycles
are equivalent to the number of flights minus the number of starts). The limits
specified in Paragraph 3.D. (Ref. Tables 1 and 2) are in terms of full cycles.
Accumulated abbreviated cycles are summated in terms of full cycles by means of
a formula and tabulated factors.
v A full cycle is defined as an engine start followed by one flight then shutdown.
v An abbreviated cycle is less severe than a full cycle. To benefit from this, an
Abbreviated Cycle Factor (ACF) is listed in the table below, and used in the
formula which determines accumulated total cycles;
v A Flight Count Factor is a multiplying factor that can be used to credit or debit life
to the components listed in the Life Service Tables to reflect the aircraft
application of the engine. This factor can also be specific to an operator that
diverges from the standards as missions.

P&WC No. N/A

Sep 03/1975 PT6A-72-3002
Revision No. 24: Sep 10/2002 © 1975 Pratt & Whitney Canada Corp. Page 1 of 8
PRINTED IN CANADA
 PRATT & WHITNEY CANADA

SERVICE BULLETIN
P&WC S.B. No. 3002R24
TURBOPROP ENGINE
ROTOR COMPONENTS - SERVICE LIFE

1. Planning Information (Cont’d)

v When abbreviated cycles are not recorded, each flight is considered to have been
preceded by one start, i.e., each flight is equivalent to a full cycle.

(4) The LCF life limits listed in the tables below are incorporated in the Type Approval
as issued by Transport Canada. Transport Canada must approve changes to rotor
component cyclic lives.

(5) Operators having missions which include many touch-and-go flights, or a frequency
of scheduled in-flight shutdowns (such as used within training missions) or which
include more than 10 flights per hour, must submit their mission profiles to Pratt &
Whitney Canada Inc. for life cycle analysis.

(6) The same component (e.g. disk, Hub, Impeller, etc.) may be installed in different
models, providing the part number is authorized to be installed in the specific
engine models (Ref. applicable Service Bulletin). Operators transferring rotating
components between engine models governed by different SBs must adhere to the
lower of the LCF life limits published in the applicable SBs.

NOTE: No ST6 (I&M) engine LCF parts maybe transferred to a flight (PT6)
engine.

E. Compliance

The service lives quoted in the Accomplishment Instructions are incorporated by

reference in the type approval as issued by the Canadian Department of Transport.
Compliance with these instructions is therefore necessary to maintain conformity with the
approval type design and the validity of the airworthiness certification.

F. Approval

Transport Canada has reviewed and approved the technical contents of this Service
Bulletin.

NOTE: This Service Bulletin is incorporated by reference in one or more Transport

Canada, Aircraft Engine Type Approvals and the service lives thereby constitute
limits applicable to the corresponding engines, modules and components
which embody only parts listed in the Transport Canada approved parts list, as
promulgated in the applicable Illustrated Parts Catalog and Service Bulletins.
Operators requiring approval for incorporation of parts not listed will be required
to substantiate to their local Airworthiness Authority the applicability of the
lives of the substitute parts and associated parts and assemblies.

G. Weight and Balance

None.

Sep 03/1975 PT6A-72-3002

Revision No. 24: Sep 10/2002 Page 2 of 8
 PRATT & WHITNEY CANADA

SERVICE BULLETIN
P&WC S.B. No. 3002R24
TURBOPROP ENGINE
ROTOR COMPONENTS - SERVICE LIFE

1. Planning Information (Cont’d)

H. Electrical Load Data

Not changed.
I. Software Accomplishment Summary

Not applicable.
J. References
Applicable PT6A Technical Manuals
K. Publications Affected
Applicable PT6A Technical Manuals
L. Interchangeability and Intermixability of Parts

Not applicable.
Interchangeability - Refer to Para. 2.D.
Intermixability - Not changed.
2. Material Information

A. Industry Support Information

Not applicable.
B. Material - Cost and Availability

Not applicable.
C. Manpower

Not applicable.
D. Material Necessary for Each Engine

Not applicable.
E. Reidentified Parts

None.
F. Tooling - Price and Availability

Not applicable.

Sep 03/1975 PT6A-72-3002

Revision No. 24: Sep 10/2002 Page 3 of 8
 PRATT & WHITNEY CANADA

SERVICE BULLETIN
P&WC S.B. No. 3002R24
TURBOPROP ENGINE
ROTOR COMPONENTS - SERVICE LIFE

3. Accomplishment Instructions

A. Accumulated total cycles and all flights and starts must be recorded in the appropriate
engine log book.

B. Turbine disk assemblies removed for repair must be suitably tagged, stating the total
number of flights, engine starts and/or the calculated total cycles, per Paragraph 3.D.
and 3.E.

C. Rotor components with lives greater than the limits shown in Tables 1 and 2, or rotor
components not supported with proper documentation, are to be removed from
service.

D. The limits shown in Table 1 in terms of number of cycles apply to PT6A-38, -41, -42,
-42A engines only.

TABLE 1, Rotor Components - Service Life Limits

Abbr’d Flight Life Limits
Detail Part Cycle Count No. Of
Description No. Engine Model Factor Factor Cycles
Hub, Compressor 3023611 PT6A-38, -41 3 1 20,000
(1st Stage)
3021911 PT6A-38, -41 3 1 20,000
3030356 PT6A-42 3 1 5,000
3036611 PT6A-41, -42 3 1 5,500
3036911 PT6A-42 3 1 5,500
3039811 PT6A-38, -41 3 1 20,000
3041611 PT6A-38, -41 3 1 20,000
Rotor, Compressor 3035801 PT6A-41, -42 3 1 30,000
3040501 PT6A-41, -42 3 1 30,000
3041501 PT6A-41, -42 3 1 30,000
3053921-01 PT6A-41, -42, -42A 3 1 20,000
Disk, Compressor 3023112 PT6A-38, -41, -42, 3 1 20,000
(2nd Stage) -42A
3031912 PT6A-41, -42, 3 1 20,000
Disk, Compressor 3023113 PT6A-38, -41, -42, 3 1 20,000
(3rd Stage) -42A
3031913 PT6A-41, -42 3 1 20,000

Sep 03/1975 PT6A-72-3002

Revision No. 24: Sep 10/2002 Page 4 of 8
 PRATT & WHITNEY CANADA

SERVICE BULLETIN
P&WC S.B. No. 3002R24
TURBOPROP ENGINE
ROTOR COMPONENTS - SERVICE LIFE

3. Accomplishment Instructions (Cont’d)

TABLE 1, Rotor Components - Service Life Limits (Cont’d)

Abbr’d Flight Life Limits
Detail Part Cycle Count No. Of
Description No. Engine Model Factor Factor Cycles
Impeller, 3017463 PT6A-38, -41, -42 3 1 20,000
Centrifugal
3031945 PT6A-38, -41, 42 3 1 20,000
3035635 PT6A-38, -41, -42 3 1 20,000
3036098 PT6A-38, -41, -42 3 1 20,000
3036793 PT6A-38, -41, -42, 3 1 20,000
-42A
Disk, Compressor 3017711 PT6A-38, -41, -42 10 1 12,000
Turbine
3024711 PT6A-41, -42 10 1 20,000
3041431 PT6A-41, -42 10 1 10,000
3049291-01 PT6A-41, -42, 10 1 10,000
PT6A-42A
Disk, Power Turbine 3022812 PT6A-38, -41, -42 10 1 8,000
(1st Stage)
3029312 PT6A-38, -41, -42, 10 1 30,000
-42A
3030812 PT6A-41 10 1 4,500
3031112 PT6A-41 10 1 8,000
3058922-01 PT6A-41, -42 10 1 8,000
Disk, Power Turbine *3022813 PT6A-38, -41, -42 10 1 8,000
(2nd Stage)
3029313 PT6A-38, -41, -42, 10 1 30,000
-42A
3030813 PT6A-41 10 1 4,500
3031113 PT6A-41 10 1 8,000
3058923-01 PT6A-41, -42 10 1 8,000
* Second-stage power turbine disk P/N 3022813, S/N 1899, having heat code PWHWL, was
installed on PCE-79194 engine and must be removed from service at first engine overhaul.

Sep 03/1975 PT6A-72-3002

Revision No. 24: Sep 10/2002 Page 5 of 8
 PRATT & WHITNEY CANADA

SERVICE BULLETIN
P&WC S.B. No. 3002R24
TURBOPROP ENGINE
ROTOR COMPONENTS - SERVICE LIFE

3. Accomplishment Instructions (Cont’d)

E. The limits shown in Table 2 in terms of number of cycles apply to the PT6A-45A, -45B
and -45R engines.

TABLE 2, Rotor Components - Service Life Limits

Abbr’d Flight Life Limits
Detail Part Cycle Count No. Of
Description No. Engine Model Factor Factor Cycles
Hub, Compressor 3021911 PT6A-45A, -45B, 3 1 20,000
(1st Stage) -45R
* 3023611 PT6A-45A, -45B, 3 1 20,000
-45R
* 3039811 PT6A-45A, -45B, 3 1 20,000
-45R
3041611 PT6A-45A, -45B, 3 1 20,000
-45R
Disk, Compressor * 3023112 PT6A-45A, -45B, 3 1 20,000
(2nd Stage) -45R
3031912 PT6A-45A, -45B, 3 1 20,000
-45R
Disk, Compressor * 3023113 PT6A-45A, -45B, 3 1 20,000
(3rd Stage) -45R
3031913 PT6A-45A, -45B, 3 1 20,000
-45R
Impeller, * 3017463 PT6A-45A, -45B, 3 1 20,000
Centrifugal -45R
3031945 PT6A-45A, -45B, 3 1 20,000
-45R
* 3035635 PT6A-45A, -45B, 3 1 20,000
-45R
* 3036098 PT6A-45A, -45B, 3 1 20,000
-45R
* 3036793 PT6A-45A, -45B, 3 1 20,000
-45R
Disk, Compressor 3041431 PT6A-45A, -45B, 10 1 10,000
Turbine -45R

Sep 03/1975 PT6A-72-3002

Revision No. 24: Sep 10/2002 Page 6 of 8
 PRATT & WHITNEY CANADA

SERVICE BULLETIN
P&WC S.B. No. 3002R24
TURBOPROP ENGINE
ROTOR COMPONENTS - SERVICE LIFE

3. Accomplishment Instructions (Cont’d)

TABLE 2, Rotor Components - Service Life Limits (Cont’d)

Abbr’d Flight Life Limits
Detail Part Cycle Count No. Of
Description No. Engine Model Factor Factor Cycles
3024711 PT6A-45A, -45B, 10 1 20,000
-45R
3049291-01 PT6A-45A, -45B, 10 1.06 10,000
-45R
Disk, Power Turbine 3022812 PT6A-45A 10 1 8,000
(1st Stage)
3029312 PT6A-45A, -45B, 10 1 30,000
-45R
Disk, Power Turbine 3022813 PT6A-45A 10 1 8,000
(2nd Stage)
3029313 PT6A-45A, -45B, 10 1 30,000
-45R
* These components only are eligible for the use of airline flight cycle factor of 0.8 used in Para.
G

F. At repair and overhaul, component life is calculated in accordance with the following
formula:

Accumulated
Total Cycles
= [ No. of
Starts
+ (
No. of Flights - No. of Starts
Abbreviated Cycle Factor ) ]
X Flight Count Factor

EXAMPLE:

Part No. 3024711 (Disk)

Abbreviated Cycle Factor 10
No. of Starts 3000
No. of Flights 9000
Flight Count Factor 1

Accumulated
Total Cycles
= [ 3000 + ( 900010- 3000 ) ] X 1
= [3000 + 600] X 1
= 3600

Sep 03/1975 PT6A-72-3002

Revision No. 24: Sep 10/2002 Page 7 of 8
 PRATT & WHITNEY CANADA

SERVICE BULLETIN
P&WC S.B. No. 3002R24
TURBOPROP ENGINE
ROTOR COMPONENTS - SERVICE LIFE

3. Accomplishment Instructions (Cont’d)

G. For airlines with approved airline flight cycle factor of 0.8 1 component life is calculated
in accordance with the following formula:

Accumulated
Total Cycles
= [ No. of
Starts
+ (
No. of Flights - No. of Starts
Abbreviated Cycle Factor ) ]
X
Flight Count Airline Flight
Factor
x
Cycle Factor
EXAMPLE:

Part No. 3023611 (Hub)

Abbreviated Cycle Factor 3
No. of Starts 3000
No. of Flights 9000
Flight Count Factor 1
Airline Flight Cycle Factor 0.8

Accumulated
Total Cycles
= [ 3000 + ( 9000 3- 3000 ) ] X 1 X 0.8
= [3000 + 2000] X 1 X 0.8

= 4000
H. Deleted

I. Service Life Marking Method:

(1) All rotor components must be marked in accordance with the applicable overhaul
manual, using the following codes:

(a) Total Cycles

Using a ‘‘CY’’ prefix, mark the total cycles accumulated between each shop
visit, rounded to the nearest 100 cycles, with the last two digits dropped and
followed by a dash (-).
Therefore, a part having cycles between visits of 525 cycles, 1819 cycles
and 1972 cycles would be marked as CY5-18-20-, which equals approximately
4300 cycles.

J. Deleted.

4. Appendix

Not applicable.

Sep 03/1975 PT6A-72-3002

Revision No. 24: Sep 10/2002 Page 8 of 8