Field Guide for

Lubrication System Debris

GE90 . GEnx . CF6 . CF34 . CT7

Tool number: GEK 113993

Date: August 2006
 This guide is to aid Airline
Line Maintenance Personnel
with the identification of
lubrication system debris on
GE Engines. Engine specific
limitations and acceptance
or non-acceptance criteria
are only found in the Engine
Manuals and/or Aircraft
Maintenance Manuals.

1
GE Proprietary Information
The information contained in this document is GE proprietary
information and is disclosed in confidence. It is the property of GE
and shall not be used, disclosed to others or reproduced without
the express written consent of GE, including, but without limitation,
it is not to be used in the creation, manufacture, development, or
derivation of any repairs, modifications, spare parts, designs, or
configuration changes or to obtain FAA or any other government
or regulatory approval to do so. If consent is given for reproduction
in whole or in part, this notice and the notice set forth on each page
of this document shall appear in any such reproduction in whole or
in part.

GE90-115B

Copyright (2006) General Electric Company, U.S.A.

2
Table of Contents
1. Contact Information Page 5
2. Handling, Collection and Inspection Page 8
3. Magnetic Sensor Quantification Page 14
4. Scavenge Screen Quantification Page 16
5. Turbine Oil Identification Page 17
6. Debris Identification Page 18
7. Definitions Page 42
8. Frequently Asked Questions (FAQs) Page 43
9. Bearing Cross-sections Page 44
10. Scale Page 45

GEnx

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Introduction
This guide is intended exclusively for the owners and operators of
GE commercial 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 supercede or replace any FAA
approved documents. This document and the material within it
are subordinate to Aircraft and Engine Maintenance Manuals.

CF34-8E

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Contact Information
If assistance is needed with this guide or with material
identification, please contact:

Customer Support Center (CSC)

GE Infrastructure - GE Aviation
USA Telephone: 1-877-GEAECSC (1-877-432-3272)
International Telephone: 1-513-552-3272
Electronic mail: geae.csc@ae.ge.com

This Guide Produced by:

GE Aviation
Commercial Engine Operations
Product Support Engineering
Bearing-Seals-Drives Cross
Product Team (BSD CPT)

CF6-80C2
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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.
Note: Debris from the same source may appear different depending
upon where it is located (such as if it was found in the scavenge
screens versus on the magnetic detectors). These differences may
be due to the fact that it passed through a lube pumpwhich
flattened or rolled the debris.

CF34-3
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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

CT7

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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, GE
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 GE 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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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.
GE 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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Oil Sampling Guidelines
Use a clean glass or plastic container for oil samples.
Label the container with the name of the airline, engine model,
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 Debris Collection
GE 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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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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Turbine Jet Engine Oil Identification
This photograph depicts the color of fresh oil for many commonly
used oils.
Note: 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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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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4 Examples of Shoulder Wear Distress

mm mm

20 20

16 16

12 12

8 8

4 4

0 0
0 .25 .5 .75 1 0 .25 .5 .75 1

mm mm

20 20

16 16

12 12

8 8

4 4

0 0
0 .25 .5 .75 1 0 .25 .5 .75 1

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4 Examples of Spall Distress

mm mm

20 20

16 16

12 12

8 8

4 4

0 0
0 .25 .5 .75 1 0 .25 .5 .75 1

mm mm

20 20

16 16

12 12

8 8

4 4

0 0
0 .25 .5 .75 1 0 .25 .5 .75 1

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M50NiL
General Characteristics:
Magnetic
Appearance:
Metallic
Reflective
Flakes
Powder

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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M50
General Characteristics:
Magnetic
Appearance:
Metallic
Dull
Small flakes and/or powder
Dark in color

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Bearing Spall Chips
General Characteristics:
Magnetic
Appearance:
Metallic Flakes
Flattened Oval
Ragged Edges Coined
Smooth or reflective on one
side, dull on the other

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Bearing Cage
General Characteristics:
Magnetic
Appearance:
Metallic
Sharp edges
Structural in shape
Smooth
Reflective
Shiny or discolored coating
Representative photo - quantity and appearance may vary.
20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Gearbox Debris
General Characteristics:
Magnetic
Appearance:
Metallic
Reflective
Flakes
Irregular
Sharp

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Machining Debris
General Characteristics:
Magnetic or non-magnetic
Appearance:
Metallic
Reflective
Irregular

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Silver Plate
General Characteristics:
Non-magnetic
Appearance:
Metallic
Reflective
Foil
Malleable
Irregular

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Silver Slivers
General Characteristics:
Non-magnetic
Appearance:
Metallic
Reflective
Filiform
Thread-like

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Carbon (Coke)
General Characteristics:
Non-magnetic
Appearance:
Non-metallic Usually black
Round Brittle to hard
Solid Oily smell
Jagged edges

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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PTFE (Teflon) Seal
General Characteristics:
Non-magnetic
Appearance:
Non-metallic
Long, thin
Flat
Light-weight
Strips
Curls
Representative photo - quantity and appearance may vary.
20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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PTFE (Teflon) Seal
General Characteristics:
Non-magnetic
Appearance:
Non-metallic
Chunks
Tan to black in color
Lightweight for size

Representative photo - quantity and appearance may vary.

48mm

40mm

32mm

24mm

16mm

8mm

0
0 1/2 1 1-1/2 2 2-1/2
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O-ring (Seal or Pre-formed Packing)
General Characteristics:
Non-magnetic
Appearance:
Non-metallic
Irregular
Ragged Edges
Dark
Brittle to pliable

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Wire Brush Threads
General Characteristics:
Magnetic or Non-magnetic
Appearance:
Metallic
Up to 2 inches in length
Thin
Cylindrical
Strong
Flexible
Representative photo - quantity and appearance may vary.
48mm

40mm

32mm

24mm

16mm

8mm

0
0 1/2 1 1-1/2 2 2-1/2
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Pump Failure
General Characteristics:
Magnetic or Non-magnetic
Appearance:
Metallic
Irregular
Reflective
Bronze in appearance

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Carbon Seal
General Characteristics:
Non-magnetic
Appearance:
Non-metallic
Irregular
Dark grey to black
Frayed

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Composite Material
General Characteristics:
Non-magnetic
Appearance:
Non-metallic
Irregular
Brittle
Ragged sharp edges

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Grit Blasting Material
General Characteristics:
Non-magnetic
Appearance:
Non-metallic
Granular
Quartz-like
Solid
Irregular

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Nickel Graphite
General Characteristics:
Non-magnetic
Appearance:
Dull
Uniform
Powder
Dark in color

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Aluminum
General Characteristics:
Non-magnetic
Appearance:
Powder to granular
Reflective
Small particles

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Tumbling Media
General Characteristics:
Non-magnetic
Appearance:
Non-metallic
Rounded, triangular, spherical
Various colors (grey, brown, blue, etc.)
Hard, smooth surface
Size ranges from a few millimeters to over an inch.

Representative photo - quantity and appearance may vary.

20mm

16mm

12mm

8mm

4mm

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.

20mm

16mm

12mm

8mm

4mm

0
0 0.25 0.5 0.75 1
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Definitions
Brittle Easily broken, cracked, or snapped
Chunks A short thick piece or lump
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
Flake A thin flattened piece or layer
Flattened Thin versus length or width
Fraying To wear or separate usually at the edges
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
Machine Curl Material formed in a spiral or winding shape
Machined Shaped as if by machine or mill tools
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
Round Edges are roughly equidistant from the center
Sharp Having a thin edge or fine point
Shiny Bright in appearance
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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Four frequently asked questions (faqs)
Why isnt hardware location identified along with the debris?
This guide is being produced for multiple 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.

Why isnt debris identified as acceptable or unacceptable?

Some debris may be acceptable to one engine model, but not to
another. Additionally, Engine and Aircraft Maintenance Manual
limits frequently change.

How can failure mode be identified?

Even for the experts, determining 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.

Will this guide be updated to include other features?

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 CSC (see page 5) with your comments. The CSC will
help the Bearing-Seals-Drives Cross Product Team (BSD CPT)
collect this information for inclusion in the next updated guide.

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Bearing Cross-sections
1. Outer Race
2. Inner Race
3. Rolling Element Roller 1
4. Rolling Element Ball
5. Cage
6. Shoulder 6 4 5

6
3 5

2
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Scales
40mm

30mm

20mm

10mm

0
0 10mm 20mm 30mm 40mm 50mm 60mm 70mm

40mm

30mm

20mm

10mm

0
0 .5 1 1.5 2 2.5 3

45