Field Guide for
Lubrication System Debris
Boeing Programs
CFM56-2 CFM56-3 CFM56-7
Tool Number: GEK 119193
February 2018
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 Safran Aircraft
Engine (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
8
Contact information
10
Handling, collection and inspection
15
Magnetic sensor quantification
17
Scavenge screen localization
21
Scavenge screen quantification
24
CFM MCD inspection guidelines
29
Debris identification
77
Definitions
Bearing cross-sections
79
Appendix
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
EASA/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)
GE Aviation
Regions covered: North America, South America, Asia Pacific and China
Toll-free in U.S.: +1 877-432-3272
Phone: +1 513-552-3272
China & Asia Pacific: +86 21-3877-7666
Email: aviation.fleetsupport@ge.com
Safran Aircraft Engines (formerly Snecma)
Regions covered: Africa, Middle East and Europe
Tel: +33 (0) 1 64 14 88 66
Email: cfm.csc@safrangroup.com
A.O.G. Fax : 33 1 64 14 84 00
Customer Support Portal: https://mycfmportal.com
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 ½ 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.
0
1
2
3
4
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.
0
1
2
3
4
5
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CFM56-2 Scavenge screen localization
Identify the sump origin of the debris.
Lubrication Unit
FWD
TGB
AGB
AFT
Sump
Forward
Sump
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CFM56-3 Scavenge screen localization
Identify the sump origin of the debris.
Lubrication Unit
FWD
AGB/TGB
Forward
Sump
AFTSump
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CFM56-7B Scavenge screen localization
Identify the sump origin of the debris.
Lubrication
Unit
Lubrication Unit
FWD
AGB/TGB
Forward
Sump
Rear Sump
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CFM56-7B27A Scavenge screen
localization
Identify the sump origin of the debris.
See previous slide for sump localization.
Lubrication
Unit
TGB
AGB
Rear Sump
AGB
Forward
Sump
Scavenge MCDs
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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.
0
1
2
3
4
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
• Particles within this table, don’t need to be sent for analysis
• Machined chips are serviceable whatever the size
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CFM MCD guidelines
AMM marginal conditions
Note: For CFM56-7B, engine oil is shared with the starter.
Particles analysis is not sufficient to determine status on
engine/AGB/TGB serviceability. Starter troubleshooting and
engine history review is required to avoid unnecessary
engine/AGB/TGB removal
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CFM MCD guidelines
AMM unsatisfactory conditions
Note: For CFM56-7B, engine oil is shared with the starter.
Particles analysis is not sufficient to determine status on
engine/AGB/TGB serviceability. Starter troubleshooting and
engine history review is required to avoid unnecessary
engine/AGB/TGB removal
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Examples of Bearing shoulder
wear distress
mm
mm
20
20
16
16
12
12
8
8
4
4
0
0
.25”
.5”
.75”
1”
mm
mm
20
20
16
16
12
12
8
8
4
4
0
.25”
.5”
.75”
1”
.25”
.5”
.75”
1”
0
.25”
.5”
.75”
1”
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Examples of Bearing spall distress
mm
mm
20
20
16
16
12
12
8
8
4
4
0
0
.25”
.5”
.75”
1”
mm
mm
20
20
16
16
12
12
8
8
4
4
0
.25”
.5”
.75”
1”
.25”
.5”
.75”
1”
0
.25”
.5”
.75”
1”
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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
0
0.25”
0.5”
0.75”
1”
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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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CFM56-7B M50 on Starter Magnetic Plug
General characteristics
• Magnetic
Note: This Magnetic Plug is limited to a CFM56-7B AGB only, not
all CFM models
Representative photo - quantity and appearance may vary
Clean/Acceptable*
Light Fuzz/Acceptable*
Moderate
Fuzz/Acceptable*
Major Metal/Unacceptable*
*: Refer to
CFM56 AMM
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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
0
0.25”
0.5”
0.75”
1”
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Bearing Cage
General characteristics
• Magnetic
Note: This finding is limited to a CFM56-3 TGB only, not all CFM
models
Representative photo - quantity and appearance may vary
20 mm
16 mm
12 mm
8 mm
4 mm
0
0
0.25”
0.5”
0.75”
1”
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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
0
0.25”
0.5”
0.75”
1”
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CFM56-3 TGB rivet
General characteristics
• Non-magnetic
Appearance
• Hollow rivet tail
Representative photo - quantity and appearance may vary
5 mm
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CFM56-3 AGB Starter Pad Brg Cage Rivet
General characteristics
• Magnetic
Appearance
• Piece of rivet - 0.67 in (17mm)
Representative photo - quantity and appearance may vary
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No. 2 Bearing nut spirolock
General characteristics
• Magnetic
Appearance
• Wire
Representative photo - quantity and appearance may vary
1 mm
5 mm
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CFM56-3 AGB starter ball bearing cage
General characteristics
• Magnetic
Appearance
• Piece of rivet
Representative photo - quantity and appearance may vary
1 mm
1 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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No. 3 BearingF orward Stationary Air Oil
Seal - PTFE (Teflon®)
General characteristics
• Non-magnetic
Appearance
• Non-metallic
• Tan to black in color
• Chunks
• Lightweight for size
1 mm
1 mm
1 mm
1 mm
Representative photos - quantity and appearance may vary
Delaminated/Missing Seal Material
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Other 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”
1-1/2”
2”
2-1/2”
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Epoxy bonding / bushing sleeve / Fwd
Air/Oil seal
General characteristics
• Non-magnetic
Appearance
• Brown/Reddish
View A-A
Representative photo - quantity and appearance may vary
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CFM56-2/3 No. 3 Brg Aft Stationary
Air/Oil Seal - Abradable and Fiberglass
General characteristics
• Non-magnetic
Appearance
• Reddish-Brown Plastic and fibrous debris
• Glass fiber with polyamide
Representative photo - quantity and appearance may vary
View A-A
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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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CFM56-3 TGB roller bearing
crimped retaining ring
General characteristics
• Magnetic
Appearance
• Black, flat curled with machining traces
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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CFM56-2A/B/C Bearing cage and Rivet
of N2 Alternator
General characteristics
• Magnetic
Appearance
• Rivet heads
Representative photo - quantity and appearance may vary
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AGB or TGB 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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CFM56-3 TGB Ball Bearing Vespel Nut
General characteristics
• Non-magnetic
Appearance
• Filiform, Brown Debris
• Resin Polyimide
Representative photo - quantity and appearance may vary
slice
TGB
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AGB/TGB Input Bevel Gear Roller Bearing
Cage
General characteristics
• Magnetic
Appearance
• Rectangular Silver Plated
1 mm
1 mm
Representative photo - quantity and appearance may vary
TGB Input Bevel Gear
Roller Bearing
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Key Lock from AGB or TGB Stud or Insert
General characteristics
• Magnetic
Appearance
• Flat piece with castellated portion
1 mm
Representative photo - quantity and appearance may vary
1 mm
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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Pins used in Inlet Gear Box Oil Nozzles
General characteristics
• Magnetic
Appearance
• Tapered Hollow Pin
Representative photo - quantity and appearance may vary
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CFM56-7B No. 3 Brg Support or ball
Bearing spanner nut locker
General characteristics
• Magnetic
Appearance
• Hexagonal nut 1/4 in.
Representative photo - quantity and appearance may vary
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No. 4 Bearing Outer Race retaining nut
Snap Ring
General characteristics
• Magnetic
Appearance
• Wire
Representative photo - quantity and appearance may vary
1 mm
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No. 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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LPT Aft Sump Abradable Coating
Material from Air or Oil Seals
General characteristics
• Non-magnetic
Appearance
• Grey and Granular
Representative photo - quantity and appearance may vary
1 mm
5 mm
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Oil Inlet Cover Gasket Material
General characteristics
• Graphite Paper with metal lamination
Appearance
• Laminated
Representative photo - quantity and appearance may vary
Oil Inlet Cover Gasket
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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 or cut wire
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
• Chips with Anodizing
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
0
0.25”
0.5”
0.75”
1”
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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
0
0.25”
0.5”
0.75”
1”
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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
0
0.25”
0.5”
0.75”
1”
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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
0
0.25”
0.5”
0.75”
1”
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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
0
0.25”
0.5”
0.75”
1”
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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
0
0.25”
0.5”
0.75”
1”
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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
0
0.25”
0.5”
0.75”
1”
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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
0
0.25”
0.5”
0.75”
1”
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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
CFM International / 75
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Bearing cross-sections
1
Outer race
4
Rolling element - ball
2
Inner race
5
Cage
3
Rolling element - roller
6
Shoulder
1
6
4
5
2
1
6
3
5
2
CFM International / 76
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Appendix
CFM International / 77
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Safe handling of oil
Most lubricants are labeled as potentially harmful when absorbed
through the skin or swallowed. Follow your company’s hazardous
material procedures as well as Oil Manufacturer’s 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.
CFM International / 78
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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
CFM International / 79
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Scales
40 mm
30 mm
20 mm
10 mm
0
0
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”
1.5”
2”
2.5”
3”
CFM International / 80
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