SAA

DIR:-10164377

Field Guide for

Lubrication System Debris
Airbus Programs

CFM56-5A CFM56-5B CFM56-5C

Tool Number: GEK 119194

November 2012
Basic

About this guide

This guide is to aid Operator Line Maintenance Personnel with

the identification of lubrication system debris on CFM56
Engines.
Engine specific limitations and acceptance or non-acceptance
criteria are only found in the Engine Manuals and/or Aircraft
Maintenance Manuals.

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CFM56 Proprietary Information

CFM, CFM56, LEAP and the CFM logo are trademarks of CFM
International, a 50/50 joint company between Snecma (Safran
group) and GE. The information in this document is CFM
Proprietary Information and is disclosed in confidence. It is the
property of CFM International and its parent companies, and shall
not be used, disclosed to others or reproduced without the
express written consent of CFM. If consent is given for
reproduction in whole or in part, this notice shall appear in any
such reproduction in whole or in part. The information contained
in this document may also be controlled by the U.S. and French
export control laws. Unauthorized export or re-export is
prohibited.

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Table of contents
6

Introduction

Contact information

10

Handling, collection and inspection

15

Magnetic sensor quantification

17

Scavenge screen quantification

20

CFM MCD inspection guidelines

25

Debris identification

60

Definitions

66

Appendix
Bearing cross-sections
Turbine jet engine oil identification
Scale

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Introduction
This guide is intended exclusively for the owners and operators
of CFM56 aero turbo machinery. It has been prepared as a guide
for use in the analysis of debris collected from or generated by
the lubrication system of these engines. The purpose of this
guide is to enable quick and accurate identification of
contaminates and debris material.
The visual identification of debris is a valuable skill, but can not
substitute for laboratory analysis to confirm material
identification.
The data presented here does not supersede or replace any FAA
approved documents. This document and the material within it
are subordinate to Aircraft and Engine Maintenance Manuals.

Hardware location
Hardware location is not included for all debris noted. This guide
is produced for multiple CFM engine lines and material from one
engine location may not correspond to a different engine.
Additionally, in the future hardware may be redesigned with
different materials.

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Introduction (cont.)
Debris acceptability/serviceability
Some debris may be acceptable to one engine model, but not to
another. Additionally, Engine and Aircraft Maintenance Manual
limits are subject to change. Refer to applicable AMM

Failure mode determination

Determination of failure mode (or root cause) can be difficult.
While certain failures leave clear evidence, many others are
difficult to identify. This guide has included some failure mode
data, but determining root cause often requires information from
many sources not just debris.

Updates to this guide

This guide will be updated and new versions will be published
periodically. Suggestions and recommendations are welcome. If
you have suggestions or interesting debris photos, please contact
the CFM Customer Support Center with your comments. The CSC
will help collect this information for inclusion in the next updated
guide.

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Contact information

If assistance is needed with this guide or with material

identification, please contact:

Customer Support Center (CSC)

CFM56 Infrastructure CFM56 Aviation
USA telephone: 1 (877) GEAE-CSC or 1 (877) 432-3272
International telephone: 1 (513) 552-3272
Email: [email protected]
This guide is produced by CFM Product Support Engineering

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Debris collection
Collection of debris is primarily accomplished via magnetic
detectors and/or scavenge screens. See AMM for proper
assembly and disassembly techniques.
If debris is found, proper tracking and collection is critical to
determining which hardware needs to be inspected or replaced.

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Handling, collection and inspection

Debris can be difficult to locate and easy to misplace. In some
cases, oil may be toxic or dangerous. For these reasons, CFM56
recommends the use of specific tools to aid in the safe and
proper handling of debris. Included on the next few pages are
some examples of the tools and tips used by CFM56
professionals to handle, collect and inspect debris.
Note: Visually inspecting debris while it is in the filter is not
recommended. Back-flushing of filter or cutting open per
approved procedures to aid visual identification is preferred.

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Oil sampling guidelines

Use a clean glass or plastic
container for oil samples.

Label the container with the

name of the operator, engine mode,
engine serial number, the sample
date and the name of the oil
in use.
If possible, take the sample within
30 minutes of shutdown.
Clean dirt from the outside of the
sampling port prior to taking sample.
Do not sample the initial 20 ml of oil. If
possible, take the sample from the middle, center of the tank.

Preferable minimum sample quantity is 120 ml (which equals

4 oz or cup).
Do not use a funnel that is contaminated, unless it was
thoroughly cleaned with alcohol (or other solvent).
Leave some air in the container for expansion of the sample
during shipping.
Put strong tape over the gap between the container and its lid
to prevent spillage.
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Debris collection tools

Collection tools may include tweezers, petri dishes, dowels and
special one-sided tape. Utilization of sterile tools reduces the
likelihood of contamination and improves the accuracy of
laboratory analysis.
Note: Utilizing office, transparency or other tapes is not
recommended because laboratory analysis requires dissolving
the tape which takes time and requires the use of stronger
chemicals. Specially designed carbon tabs are recommended.

Carbon tabs with backing removed

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Debris inspection tools

10X (or higher) magnification is recommended, but not always
needed. This photograph shows three suitable examples of
magnifying devices that may be valuable to line maintenance
personnel.
A magnet may also be valuable for identifying the magnetic
properties of debris.

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Field magnetic sensor collection

CFM56 strongly recommends sending debris to certified

laboratories for identification; however, the following steps may
be followed if field data is needed and/or if laboratory analysis is
not possible.
Note date, aircraft, engine number/position and chip detector
prior to removing debris.

Lightly press carbon tabs to debris on sensor.

Under controlled conditions, remove debris from carbon tabs
and degrease debris.
Use sieves to determine debris size. If sieves are not available,
place debris on grid and take high-resolution photographs

Note quantity and size of debris.

Refer to Engine and Aircraft Maintenance Manuals for
disposition.
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Magnetic sensor quantification

Shoulder wear
This relative scale can be utilized when communicating magnetic
sensor debris levels.
Note: These photographs depict one type of sensor. Different
engine models may have differently shaped sensors.

5
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Magnetic sensor quantification

Spall wear
This relative scale can be utilized when communicating magnetic
sensor debris levels.
Note: These photographs depict one type of sensor. Different
engine models may have differently shaped sensors.

5
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Scavenge screen quantification

This relative scale can be utilized when communicating screen
debris levels.
Note: Different engine models will have screens of different sizes
and shapes.

5
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General characteristics and appearance

Debris identification
The following pages show a range of debris; some of which is
rarely found, but is included for comprehensiveness.
The first two pages of photos (which show debris from events)
are included to help illustrate differences between what may be
seen on the flight line versus what is extracted in a laboratory.
This is followed by photos of magnetic and then non-magnetic
debris.
Appearance descriptions are also provided. Each material is
described as metallic or non-metallic followed by the descriptors
that most readily identify the debris.

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Bearing information
The primary objective of debris identification is for the detection
of bearing distress prior to failure. Any bearing debris
identification, either visually or by laboratory analysis, is cause
for immediate concern. The following visual characteristics can
be helpful in distinguishing bearing material.

Many chips of similar size and shape

Magnetic material
Smooth, reflective (silvery) surface on one or both sides
Roughly circular or elliptical flakes, thinner around edges
Material that is hard and brittle

Metal chunks as small dark irregular particles

Pieces of bearing cage material
Chunks of silver plated steel

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CFM MCD inspection guidelines

The decision for action must be driven by key factors:

Debris Examination
Visual aspect (shape, color, plated or not, laminated )
Nature (magnetic or non-magnetic)
Size, quantity
Oil sump source

Engine history
Low time/cycle engine since new or overhaul
Recent engine squawks
Maintenance report (past MCD findings, oil circuit
contamination )
Engine trend shift (vibes, oil consumption )

References
Applicable Aircraft Maintenance Manual
CFM56 Non-Destructive Test Manual
Part 10 Chip Analysis (CFMI-TP-NT.11)

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CFM MCD guidelines

for magnetic particles
When particles are just collected, visual inspect per 10x
magnifying lens to identify the category

Satisfactory - Serviceable
Marginal - Means continue in services while debris are sent to Lab
Unsatisfactory - Immediate action is required
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CFM MCD guidelines

AMM satisfactory conditions
Magnetic serviceable conditions
Particles within this table, dont need to be sent for analysis

Machined chips are serviceable whatever the size

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CFM MCD guidelines

AMM Non-Serviceable conditions:
Magnetic material - non-serviceable conditions
When particles are caught on the EMCD, its recommended to
install the the Mag Bars to isolate the concerned sump
See additional recommendations on next slide

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CFM MCD guidelines

AMM Non-Serviceable conditions
Magnetic material - non-serviceable conditions
These descriptions are applicable for material collected in the
Scavenge Screens or after installation of the Magnetic Bars for
each sump

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Examples of bearing shoulder

wear distress
mm

mm

20

20

16

16

12

12

0
.25

.5

.75

mm

mm

20

20

16

16

12

12

.25

.5

.75

.25

.5

.75

0
.25

.5

.75

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Examples of bearing spall distress

mm

mm

20

20

16

16

12

12

0
.25

.5

.75

mm

mm

20

20

16

16

12

12

.25

.5

.75

.25

.5

.75

0
.25

.5

.75

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M50NiL
General characteristics
Magnetic

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0.25

0.5

0.75

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M50
General characteristics
Magnetic
Appearance
Metallic

Small flakes and/or powder

Dull

Dark color

Representative photo - quantity and appearance may vary

1 mm

1 mm
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Bearing spall chips

General characteristics
Magnetic
Appearance
Metallic

Flakes

Flattened

Oval

Ragged edges

Coined

Smooth/reflective
on one side, dull on
the other

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0.25

0.5

0.75

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Gearbox debris
General characteristics
Magnetic
Appearance
Metallic

Flakes

Sharp

Reflective

Irregular

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0.25

0.5

0.75

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#2 bearing nut spirolock

General characteristics
Magnetic
Appearance

Wire

Representative photo - quantity and appearance may vary

1 mm

5 mm

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Forward sump air/oil separator

General characteristics
Non-magnetic
Appearance

Resin polyamide material (green or brown color)

Representative photo - quantity and appearance may vary

1 mm

1 mm

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Forward sump abradable

General characteristics
Non-magnetic
Appearance

Phenolic or plastic material (greenish-white color)

Representative photo - quantity and appearance may vary

1 mm

1 mm

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Bearing air/oil seal abradable

General characteristics
Non-magnetic
Appearance

Glass fiber with polyamide material with grooves

Reddish brown non-metallic

Representative photo - quantity and appearance may vary

1 mm

1 mm
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AGB/TGB keylock from insert

General characteristics
Non-magnetic
Appearance

Flat piece with castellated portion

Representative photo - quantity and appearance may vary

1 mm

1 mm

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AGB bearing cage rivets

General characteristics
Magnetic
Appearance

Rivet heads

Representative photo - quantity and appearance may vary

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Sealol seal tangs

General characteristics
Magnetic
Appearance

Rectangular tang
Approximate size: 0.12 x 0.16 x 0.06 in (3 x 4 x 1.5 mm)

Representative photo - quantity and appearance may vary

1 mm

1 mm

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TGB oil nozzle

General characteristics
Non-magnetic
Appearance

Worn nozzle shown with debris

Nozzle wear due to vespel nut contact

Representative photo - quantity and appearance may vary

1 mm

1 mm
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IGB shims
General characteristics
Non-magnetic
Appearance

Shiny metallic

Representative photo - quantity and appearance may vary

1 mm

1 mm
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N4 Bearing snap ring

General characteristics
Magnetic
Appearance

Wire

Representative photo - quantity and appearance may vary

1 mm

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#4 bearing cage crimp

General characteristics
Magnetic
Appearance

Flakes

Representative photo - quantity and appearance may vary

1 mm
1 mm

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Aft air/oil separator honeycomb

General characteristics
Non-magnetic
Hastelloy X
Appearance
Pieces of honeycomb can be associated with small aluminum

Representative photo - quantity and appearance may vary

1 mm

5 mm

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Bearing cage
General characteristics
Non-magnetic

Representative photo - quantity and appearance may vary

1 mm

1 mm
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Safety cable crimp sleeve/safety wire

General characteristics
Non-magnetic
Appearance

Wire
Crimping sleeve

Representative photo - quantity and appearance may vary

1 mm

1 mm

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Shotpeening media
General characteristics
Magnetic
Appearance

Spherical steel shotpeen balls

Representative photo - quantity and appearance may vary

1 mm

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Machining debris
General characteristics
Magnetic or non-magnetic
Appearance
Metallic

Irregular

Reflective

Representative photo - quantity and appearance may vary

1 mm

1 mm
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Silver plate
General characteristics
Non-magnetic
Appearance
Metallic

Foil

Irregular

Reflective

Malleable

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0.25

0.5

0.75

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Oil inlet cover

General characteristics
Non-magnetic
Appearance
Metallic

Filiform

Silver shavings

Reflective

Thread-like

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0.25

0.5

0.75

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Carbon (coke)
General characteristics
Non-magnetic
Appearance
Non-metallic

Jagged edges

Round

Usually black

Solid

Brittle to hard

Oily smell

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0.25

0.5

0.75

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PTFE (Teflon) seal

General characteristics
Non-magnetic
Appearance
Non-metallic

Tan to black in color

Chunks

Lightweight for size

Representative photo - quantity and appearance may vary

48 mm
40 mm

32 mm
24 mm
16 mm
8 mm
0
0

1/2

1-1/2

2-1/2

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O-ring (seal or pre-formed packing)

General characteristics
Non-magnetic, elastomer
Appearance
Non-metallic

Ragged edges

Irregular

Dark

Brittle to pliable

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0.25

0.5

0.75

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Carbon seal
General characteristics
Non-magnetic
Appearance
Non-metallic

Irregular

Frayed

Granular

Dark grey to black

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0.25

0.5

0.75

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Grit blasting material

General characteristics
Non-magnetic
Appearance
Non-metallic

Quartz-like

Granular

Solid

Irregular

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0.25

0.5

0.75

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Tumbling media
General characteristics
Non-magnetic
Appearance
Non-metallic

Various colors

Rounded, triangular, Hard, smooth

spherical
surface

Size ranges from

a few millimeters
to over an inch

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0.25

0.5

0.75

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Tube cap
General characteristics
Non-magnetic
Appearance
Non-metallic

Various colors
(yellow, red, etc.)

Various
deformations

Representative photo - quantity and appearance may vary

20 mm

16 mm

12 mm

8 mm

4 mm

0.25

0.5

0.75

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Definitions
Brittle Easily broken, cracked, or
snapped

Machine Curl Material formed in a

spiral or winding shape

Chunk A short thick piece or lump

Machined Shaped as if by machine or

mill tools

Curls Pieces having a spiral or winding

form

Coined Stamped
Dull Lacking brilliance, luster or
lightness
Fibrous Capable of being separated
into fibers
Filiform Shaped like a filament or thread

Malleable Capable of being extended

or shaped
Pliable Supple enough to bend
without breaking
Powder Matter in even and fine
particles
Reflective Able to throw back light

Flake A thin flattened piece or layer

Round Edges are roughly equidistant

from the center

Flattened Thin versus length or width

Sharp Having a thin edge or fine point

Fraying To wear or separate usually at

the edges

Shiny Bright in appearance

Fuzz Very fine light particles or fibers

Granular Consisting of uniform particles
Hard Not easily penetrated
Irregular Lacking symmetry or evenness
Jagged Having a sharply uneven edge or
surface
Laminated Composed of layers of united
material

Sliver A long slender piece cut or

torn off
Solid Uniformly close and coherent
texture
Spall Wedge or irregular chip, flake
or fragment
Strips Long narrow pieces of material
Thin Measuring little in cross section
or diameter

Uniform Little variation in form

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Bearing cross-sections
1

Outer race

Rolling element - ball

Inner race

Cage

Rolling element - roller

Shoulder

1
6

2
1
6

2
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Appendix

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Safe handling of oil

Most lubricants are labeled as potentially harmful when absorbed
through the skin or swallowed. Follow your companys hazardous
material procedures as well as Oil Manufacturers guidance.
CFM56 recommends wearing safety glasses, protective clothing
and gloves when handling oil. Latex, pvc, or rubber gloves should
be powder-free to avoid contamination when taking or preparing
samples for analysis.
Note: Cotton gloves are not recommended as they can
contaminate the sample and do not protect the hands from
contact with oil.

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Turbine jet engine oil identification

This photograph depicts the color of fresh oil for many commonly
used oils.

Note: Reference only. Oil color may change under different

environmental and/or storage conditions.

BPTO
2380

AeroShell
500

AeroJet 5

AeroShell
555

AeroShell
560

Mobil
Jet II

Castrol
5000

Castrol
5050

Nycoil
600

BPTO 25

BPTO
2197

Mobil
Jet 254

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Scales
40 mm

30 mm

20 mm

10 mm

10 mm 20 mm 30 mm 40 mm 50 mm 60 mm 70 mm

40 mm

30 mm

20 mm

10 mm

0
0

.5

1.5

2.5

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