012 Cleanliness

Engineering
Standards
Engineering Standard Number
Name CLEANLINESS,PARTICLE COUNTING (FUEL SYSTEMS)
INSPECTION SPECIFICATON 16599

Identifier
(ITEM)
Abstract
This specification covers requirements for the cleanliness level of fuel systems components and
test methods.
Current Release Number Std. Revision Level

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CUMMINS INTERNAL USE ONLY
This document (and the information shown thereon) is CONFIDENTIAL AND PROPRIETARY and shall not be disclosed to others in hard copy
or electronic form, reproduced by any means, or used for any purpose without written consent of Cummins Inc.
Engineering
Standards

Identifier
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Table of Contents
Heading Page Number
Abstract .....................................................................................................................................1
Table of Contents ......................................................................................................................2
1. Scope....................................................................................................................................3
2. Applicable Documents.........................................................................................................3
3. Definitions............................................................................................................................3
4. Specifications.......................................................................................................................6
4.1. Significance and Use ...................................................................................................6
4.2. General Rules for Cleanliness Testing.........................................................................7
Table 1: Size Classes for Particle Counting (Test Methods IV, V, VI only)......................8
Table 2: Definition of Contamination Level.......................................................................9
4.3. Acceptance Criteria by Test Method .........................................................................10
Table 3: Acceptance Criteria for Gravimetric Analysis (Test Methods II, III) .................11
Table 4: Cleanliness Class Level Defined by Contamination Level/Size Range ..............12
4.4. Properties of Hard Particles .......................................................................................13
5. Additional Requirements ...................................................................................................14
5.1. Residual Magnetism ..................................................................................................14
5.2. Laboratory Approval..................................................................................................14
5.3. Preproduction Parts....................................................................................................14
Appendix A: Guidelines for Determination of Cleanliness Class /Test Method.....................15
Table A1: Guidelines for Cleanliness Class and Test Method Application ......................16
Table A2: Guidelines for Application of Test Methods ....................................................17
Table A3: Suggested Drawing Notes by Example/Situation.............................................19
Appendix B: General Requirements Test Environment/Equipment/Reagents........................22
Table B1: Equipment, Apparatus, and Reagent Requirements by Test Method ...............23
Appendix C: Test Method I (Visual Examination)..................................................................25
Appendix D: Test Method II (Flush and Brush with Gravimetric Analysis) ..........................26
Appendix E: Test Method III (Ultrasonic with Gravimetric Analysis) ...................................27
Appendix F: Test Method IV (Pressurized Spray with Particle Counting) .............................28
Appendix G: Test Method V (Internally Flowed Assembly with Particle Counting) .............30
Appendix H: Test Method VI (Internally Flowed Component with Particle Counting) .........31
Appendix I: Filter Membrane Preparation...............................................................................32
Appendix J: Filter Membrane Analysis ...................................................................................33
Appendix K: Reporting of Results...........................................................................................34

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1. Scope
This specification is primarily intended for, but not limited to fuel system components. This
specification covers requirements for the cleanliness level of components and assemblies
processed for, processed by, or supplied to Cummins Inc., Cummins Inc. suppliers or Cummins Inc.
partners.
2. Applicable Documents
Applicable documents listed below may be obtained from the respective organizations listed in
CES 10054, Standards Organizations Addresses.
a. CES 10054, Standards Organizations Addresses

b. CES 10056, Glossary
c. CES 19040, Cleaning Process
d. ISO 14644-1 and 2, Clean Rooms and Associated Controlled Environments
e. ISO 16232, Sections 1 to 10 Road Vehicles-Cleanliness of Components of Fluid Circuits
3. Definitions
Terms used in this standard that have a general definition for usage in Cummins Engineering
Standards are defined in CES 10056, Glossary.
3.1. As Received from Supplier
As received from supplier refers to components in the condition or state of arrival from an external
supplier.
3.2. Assembly
Assembly refers to a part that contains two or more components which have been fitted together to
form an intermediate of final part number.
3.3. At Point of Assembly
At point of assembly refers to components to be assembled at the point of assembly.

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3.4. Cleanliness Class Level
The cleanliness class level is a alphabetic code which is typically called out on a Cummins part
drawing. Typical designations can be: AAA, AA, A, B, or V. The cleanliness class level is
comprised of a contamination level number in each particle size category.
3.5. Cognizant Engineering Organization
Cognizant engineering organization refers to the engineering organization within Cummins that
has design authority over the parts being processed.
3.6. Cognizant Quality Organization
Cognizant quality organization refers to the quality assurance organization within Cummins Inc.
that is allied with the cognizant engineering organization and has audit, review and approval
authority over the process and quality control plant for the parts being produced.
3.7. Collection System
The collection system typically consists of the following components: pumps, filters, solvent
reservoir, spray gun able to spray clean rinsing fluid at a known and controlled flow rate.
3.8. Contamination Level
Contamination level is a number ranging from 00-24 that represents a high and low limit of particle
counts for a given size category of particles. A higher contamination level indicates more particles
are present in that particular size category.
3.9. Fiber
A fiber is an irregular shaped non-metallic soft particle (natural or synthetic) with a large length/
diameter ratio for example >30:1.
3.10. Hard Particle/Debris
Hard particle/debris is defined as particle/debris, but with the added qualities of having high
hardness as opposed to organic or fibrous debris. Examples of hard particles/debris include, but not
limited to metal chips, abrasive grit, sand, or stiff plastics.

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3.11. Membrane Filter
The membrane filter is used to collect debris for the various test methods defined by this
specification. For the purposes of this specification, the membrane is 47 mm in diameter, TMTP,
SVLP, or SMWP filter type (these are filter code designations available through Millipore Corp.)
and has a mean pore size of 5 microns or less.
a. The TMTP filter code designates 5.0 micron pore size patch made of polycarbonate
material
b. The SVLP filter code designates a 5.0 micron pore size patch made of PVDF material
c. The SMWP filter code designates a 5.0 micron pore size patch made of mixed cellulose
ester material
3.12. Particle/Debris
Particle/debris are removable with specified conditions and possessing mechanical cohesion to a
part or substrate.
3.13. Particle Counting System
Particle counting system is setup to size and count the collected particles on the membrane filters
using a microscope. Setup usually consists of a microscope system with motorized stage, a digital
camera, and image analysis software.
3.14. Rinsing Liquid
The rinsing liquid is defined by the terms of this specification to be a fluid filtered through a
1.0 micrometer or finer filter. Rinsing liquid for particle counting work should be at least two
ISO 16232 contamination levels cleaner than that of the cleanliness requirements of the
component/fluid to be inspected. A test liquid of low viscosity (/=5 mm2/s) and having the
capability of removing (or dissolving) oil and grease is recommended.

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4. Specifications
4.1. Significance and Use
4.1.1. This specification covers requirements for the cleanliness of components, test methods,
and acceptance limits.
4.1.2. This specification shall not be used unless the engineering drawing or in-process
documentation contains requirements for the following:
a. Cleanliness Class Level of the component

b. Test method for generating the sample membrane filter
c. Applicable surface area of the component preferably in mm2, cm2 or other appropriate units
d. If other than the entire surface of the part, the designated area(s) to be tested
e. Point in process at which cleanliness limits apply:
At point of assembly
As received from supplier
f. For Test Method V and VI (if for other than for all operating conditions), assembly specific
operating/sampling conditions (i.e., fluid, flow rate, sample volume, conditioning prior to
sampling)
g. Applicable volume of the part in mL (Test Method VI part prints)
h. Alternate acceptance criteria (if applicable)
4.1.3. Guidelines for cleanliness class and test method are in Appendix A: Guidelines for
Determination of Cleanliness Class /Test Method on page 15.
4.1.4. Test environment, equipment, and reagents shall be in accordance with Appendix B:
General Requirements Test Environment/Equipment/Reagents on page 22.
4.1.5. The frequency for auditing part(s) according to this specification shall be determined
by quality control plan documentation issued by the cognizant quality organization of part in
question or upon request from Fuel Systems Business Unit Materials Engineering Organization.

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4.2. General Rules for Cleanliness Testing
(All Test Methods except Test Method I)
4.2.1. The general testing procedure consists of the following steps:
a. Properly drying a membrane filter to prepare for particle extraction (for Test Methods II
and III only)
b. Extracting particles from the test part(s) or fluid sample onto a sample membrane filter
c. Properly drying the membrane filter for analysis
d. Counting, measuring the sizes, and/or weighing of particles on the filter membrane
e. Examination of filter membrane for hard particle (class AA Cleanliness Class Level only)
f. Evaluation of the test results
g. Accepting or rejecting the part(s)
h. Documenting and distributing results
4.2.2. General Condition of Cleanliness-All Classes
4.2.2.1. Parts shall be free from dirt, manufacturing debris, paint, grease, scale, grit, corrosion,
smut, soot, and any other foreign substance. Particle counts on test parts shall not exceed the
requirements of 4.2.3. Class Cleanliness Requirements on page 8. Heat temper film, corrosion
inhibitors, coatings and marking/identification substances are permitted if documented in a plan
approved by the cognizant quality organization of the purchasing plant. Components with
corrosion inhibitors and coatings applied shall meet the applicable cleanliness class, particle count,
and particle size requirements.
4.2.2.2. For Test Methods II, III, IV, V, and VI, all particles/fibers which are captured on the
prepared test membrane filters shall be counted and reported. However, upon written agreement
between cognizant engineering and quality organizations of supplier and purchaser membrane
filters containing single fibers which do not intersect each other may be excluded from the total
particle counts of the membrane filter. The purchaser and supplier shall also agree on the definition
of a fiber as well, but typically a fiber can be defined as non-metallic and having a high length to
width ratio. When particle counting the standard patch as specified in Appendix B: General
Requirements Test Environment/Equipment/Reagents on page 22 item g., if the patch exceeds
60,000 total particles, it is recommended that the patch should be discarded and another test should
be performed using a smaller sample size for better particle counting accuracy.

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4.2.2.3. The following tables are taken from ISO 16232-10 and are accurate as of the 2007
edition. If a dispute emerges between supplier and purchaser of the accuracy of Table 1: Size
Classes for Particle Counting (Test Methods IV, V, VI only) on page 8 and Table 2: Definition of
Contamination Level on page 9 what is stated in the current revision of ISO 16232 takes
precedence over Table 1: Size Classes for Particle Counting (Test Methods IV, V, VI only) on page
8 and Table 2: Definition of Contamination Level on page 9 of this engineering standard.
4.2.3. Class Cleanliness Requirements
Table 1: Size Classes for Particle Counting (Test Methods IV, V, VI only)
Size Class Size X (m)
B 5  X < 15
C 15  X < 25
D 25  X < 50
E 50  X < 100
F 100  X < 150
G 150  X < 200
H 200  X < 400
I 400  X < 600
J 600  X < 1000
K 1000  X
Taken from ISO 16232-10 (2007 Edition)

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Table 2: Definition of Contamination Level
Up to and Contamination
More Than
Including Level
0 0 00
0 1 0
1 2 1
2 4 2
4 8 3
8 16 4
16 32 5
32 64 6
64 130 7
130 250 8
250 500 9
500 1 x 103 10
1 x 103 2 x 103 11
2 x 103 4 x 103 12
4 x 103 8 x 103 13
8 x 103 16 x 103 14

Number of particles per 100 cm3 or mL or per 1000 cm2

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Table 2: Definition of Contamination Level (Continued)
Up to and Contamination
More Than
Including Level
16 x 103 32 x 103 15
32 x 103 64 x 103 16
64 x 103 130 x 103 17
130 x 103 250 x 103 18
250 x 103 500 x 103 19
500 x 103 1 x 106 20
1 x 106 2 x 106 21
2 x 106 4 x 106 22
4 x 106 8 x 106 23
8 x 106 16 x 106 24

Number of particles per 100 cm3 or mL or per 1000 cm2
4.3. Acceptance Criteria by Test Method
4.3.1. Test Method I-Visual Inspection
(Appendix C: Test Method I (Visual Examination) on page 25)
Particles larger than 0.5 mm shall not exceed one particle per 500 mm2/5cm2. In addition, particles
larger than 1.0 mm shall not exceed one particle per 2000 mm2/20 cm2.

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4.3.2. Test Methods II, III-Flush and Brush and Ultrasonic Method
(Appendix D: Test Method II (Flush and Brush with Gravimetric Analysis) on page 26,
Appendix E: Test Method III (Ultrasonic with Gravimetric Analysis) on page 27)
Table 3: Acceptance Criteria for Gravimetric Analysis (Test Methods II, III)
Maximum Allowed Maximum

Cleanliness Class Debris Weight per Maximum Particle Accumulated Debris
Level Surface Area for Size Weight for any One
Each Test Test Piece
Class B 0.0002 mg/mm2 625x375 micrometers 6.5 mg
Class A 0.0001 mg/mm2 250x125 micrometers 6.5 mg
Class AA 0.00005 mg/mm2 250x125 micrometers 4.0 mg
Examples using the acceptance criteria:

a. Part W has a surface area of 100,000 mm2/1000 cm2 so the calculated maximum allowed
debris for class A cleanliness level would be 10 mg. Since this is over the threshold limit
according to column 4 (Maximum accumulated debris weight for any one test piece), the
limit would actually be 6.5 mg.
b. Part X has a maximum particle size of 260x110 µm and has a class A cleanliness
requirement on the print and a surface area of 20,000mm2. The measured part debris
weight is 1.9 milligrams. The part passes according to debris weight criteria but the part
fails according to column 3 (maximum particle size). The result is that the parts fail the
cleanliness test.
c. Part Y has a maximum particle size 245x130 µm and a class A cleanliness requirement
on the print. The part fails according to column 3 (maximum particle size).
d. Part Z has a maximum particle size 245x120 µm and a class A cleanliness requirement
on the print. The part passes according to column 3 (maximum particle size).

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Table 4: Cleanliness Class Level Defined by Contamination Level/Size Range
Size >=
6 *µm- 15 µm- 25 µm- 50 µm- 100 µm- 150 µm- 200 µm- 400 µm- 600 µm-
1000
Range 15 µm 25 µm 50 µm 100 µm 150 µm 200 µm 400 µm 600 µm 1000 µm
µm
Size Class B C D E F G H I J K
Class B 20 19 18 16 14 12 10 9 8 3
Class A 17 16 15 13 11 9 8 6 5 0
Class AA 16 14 13 11 8 7 5 2 0 0
total
particles
Class AA Do not distinguish between hard from soft **0-10 absolute count 00
**Hard particles <200 micrometers. Overall counts not but not to exceed class
particles to exceed class AA total particle counts as stated AA total particles counts
above. as above.**
Class 12 11 10 9 7 6 5 3 1 0
AAA
Test Methods IV, V, VI
Notes:
*Size Class B (6 µm-15 µm) is specified as (5 µm-15 µm) in ISO 16232.
**Hard particles see Section 4.4. Properties of Hard Particles on page 13.

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4.4. Properties of Hard Particles
As stated in Section 3. Definitions on page 3 hard debris can be metal, sand, stiff plastic or the like.
Examination of hard particles should be done visually on a routine basis and shall be done with
incidental (top down) lighting under a microscope. The referee method in case of dispute will be
Scanning Electron Microscope (SEM)/Energy Dispersive Spectrometer (EDS) analysis which will
determine the exact chemical signature of the debris particle. Examples of hard debris include but
are not limited to metallic pieces, sand/abrasive media, or other. Some visual qualities of hard
particles are as follows.
4.4.1. Metallic Pieces
a. Shiny/reflective appearance
b. Sharp edges
c. Solid
d. May be magnetic
e. May be gray or silver in color
f. Chemical signature: predominantly iron or aluminum based alloys or others
g. Not easily breakable upon handling with tweezers under microscope
4.4.2. Sand/Abrasive Media
a. May be translucent or slightly brown if natural sand

b. May be green, gray or black if synthetic abrasive media
c. Faceted appearance with sharp edges
d. Chemical signature will mostly be silicon oxide, silicon carbide, aluminum oxide, or the
like
e. Not easily breakable upon handling with tweezers under microscope
4.4.3. Others
a. May be spalled hard coatings (Diamond Like Carbon, TiN, Nitrided white layer or the like)
b. Glass-filled polymers
c. Not easily breakable upon handling with tweezers under microscope

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5. Additional Requirements
5.1. Residual Magnetism
All components shall meet the acceptance requirements for residual magnetism in accordance with
the engineering drawing, prior to cleanliness testing.
5.2. Laboratory Approval
The supplier’s laboratory shall be reviewed and approved by Cummins Supplier Quality
Improvement (SQI) Organization. Image analysis equipment and particle counting method shall be
qualified through the Production Part Approval Process (PPAP).
5.3. Preproduction Parts
Unless otherwise approved by the Cognizant Engineering Organization, preproduction parts (parts
prior to PPAP and parts for PPAP approval) shall be supplied in the cleanliness condition specified
for the finished part (at time of assembly) on the drawing and with a test report of cleanliness
testing results.

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Appendix A: Guidelines for Determination of Cleanliness Class /Test Method
A1. Cleanliness Class

Table A1: Guidelines for Cleanliness Class and Test Method Application on page 16 and Table
A2: Guidelines for Application of Test Methods on page 17 are for use as a guide for selecting
cleanliness requirements when setting drawing requirements. Cleanliness requirements shall be
determined according to the part function/operation/risk.

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Appendix A: Guidelines for Determination of Cleanliness Class/Test Method (Continued)
Table A1: Guidelines for Cleanliness Class and Test Method Application
Applicable
Class Class Application
Test Method
Class AAA This cleanliness level applies to exceptionally debris-sensitive IV, V, VI

“Exceptionally components. For individual components, Class AAA shall
Clean” only be applied where Class A or AA has been demonstrated
to be inadequate. Typical components include fuel filters in
debris sensitive applications.
Class AA This cleanliness level applies to exceptionally debris sensitive II, III, IV, V,
“Exceedingly components. For individual components, class AA shall only VI
Clean” be applied where class A has been demonstrated to be
inadequate. Specific examples include any downstream
components from stage two filtration on fuel systems where at
injector filtration (edge filter) is not present. Example
components include: high pressure fuel lines, high pressure
pump, high pressure connector, fuel rail, fuel filters, etc.
Class A For particularly debris sensitive components (more debris II, III, IV, V,
“Precision sensitive than Class B) and fuel/oil wet components in the VI
Clean” unfiltered upstream of particularly debris sensitive
components. Typical components could include match fit
injector or pump components, other various internal injector
or pump components, fuel lines, fuel fittings, or other
components that are in the fuel wetted area of the fuel system.
Additionally should be specified on fuel filters where at
injector filtration (edge filter) is present.
Class B This classification should be used on debris sensitive II, III, IV, V,
“Functionally components and fluid contacting components in the unfiltered VI
Clean” upstream of the fuel circuit. This classification should also be
used on components in the oil circuit. Typical components
include tappets, tappet springs, and tappet spring retainers.
Class V This cleanliness level applies to parts that are not in the fluid I
“Visually path of debris sensitive parts. Typical components include
Clean” fasteners or external parts of the fuel system.

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Table A2: Guidelines for Application of Test Methods
Test Method When to Apply
I For any part or assembly.

(Appendix C:)
“Visual Inspection”
II May be applicable for in-process control or for bought out finished
(Appendix D:) (BOF) components. For measurement of cleanliness of selected
“Flush and Brush surfaces (i.e., selected internal passages of test parts, accumulators,
etc.)
Component Cleanliness”
III May be used for in-process control for BOF components. For
measurement of cleanliness on all surfaces of the component.
(Appendix E:)
“Ultrasonic Component
Cleanliness”
IV Pressurized spray inspection method used for surfaces that are in the
(Appendix F:) “line of sight” or easily accessible. This method is the preferred
method of evaluation for most critical fuel wetted Fuel Systems parts.
“Pressurized Spraying”
V Applicable to flowed assemblies, any assembly capable of creating

(Appendix G:) pressure, on a test stand such as high or low pressure pumps.
Component specific operating conditions for the Test Method V
“Internally Flowed sample collection should be defined on the drawing. Operating
Assembly Cleanliness” conditions shall include fluid type, pressures, flow rate, timing of
sampling, and any other key operating parameters that could impact
the debris generation/liberation from the assembly.
VI This method is applicable to any parts which contain internal

passages for which cleanliness is to be measured. Typical parts where
(Appendix H:) this test method shall be called out on the print include: fuel filter,
“Internally Flowed spin-on/cartridge fuel filters, fuel lines, fuel rail, etc.
Component Cleanliness”

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A2. Suggested/Template Drawing Notes

Table A3: Suggested Drawing Notes by Example/Situation on page 19 is for use as a guide/
template for writing drawing notes.

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Table A3: Suggested Drawing Notes by Example/Situation
Example/Suggested Drawing Note(s) for the Fuel System Part

Example/Situation
Situation Examples
BOF part supplied CLEANING, HANDLING & PRESERVATION High Pressure

ready to assemble SHALL BE IN ACCORDANCE WITH ENGR. connector, Fuel
in the Class A, Test STD. 19040 TO ACHIEVE CLEANLINESS PER Rail, Fuel lines
Method IV INSP. STD. 16599:
condition.
a. Surface Area = Approx. XXXX mm2
b. Class A, Test Method IV:
Component ready to CLEANING, HANDLING & PRESERVATION Internal injector
assemble in the SHALL BE IN ACCORDANCE WITH ENGR. components:
Class A Test STD. 19040 TO ACHIEVE CLEANLINESS PER injector nozzle,
Method IV INSP. STD. 16599: injector plunger,
condition. However, pilot valve seat,
this part is intended a. SURFACE AREA = APPROX: XXXX mm2 etc. internal
to be supplied to all b. AS-RECEIVED: CLASS B, TEST pump
assembly plants in components:
the Class B, Test METHOD III. pump tappet
Method III c. AT TIME OF ASSEMBLY: CLASS A, barrel, plunger,
condition. TEST METHOD IV. etc.

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Table A3: Suggested Drawing Notes by Example/Situation (Continued)

Example/Situation
Situation Examples
Assembled fuel CLEANING, HANDLING, & PRESERVATION High pressure

system pump PROCESS SHALL BE IN ACCORDANCE WITH pump assemblies
product. ENGINEERING STANDARD 19040 TO
ACHIEVE CLEANLINESS PER INSP. STD.
16599:
a. AT TIME OF ASSEMBLY: AS SPECIFIED

ON ITEM PRINT.
b. AFTER ASSEMBLY: EXTERNAL
SURFACES CLASS V, TEST METHOD I
c. AFTER COMPLETING FUNCTIONAL
TEST: INTERNAL FUEL WETTED
SURFACES SHALL BE CLASS A, TEST
METHOD V, FOR A SAMPLE OF 500
MILLILITERS OF FLUID COLLECTED
WHILE THE PUMP IS OPERATED AT A
RATED CONDITION.
Upstream fuel CLEANING, HANDLING & PRESERVATION Pump tappet,
system components, SHALL BE IN ACCORDANCE WITH ENGR. camshaft
or Oil wetted STD. 19040 TO ACHIEVE CLEANLINESS PER
component INSP. STD. 16599:
a. Surface Area = Approx. xxxx mm2

b. Class B Test Method III

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Table A3: Suggested Drawing Notes by Example/Situation (Continued)

Example/Situation
Situation Examples
Assembled injector CLEANING, HANDLING, & PRESERVATION Fuel Injector
fuel system product PROCESS SHALL BE IN ACCORDANCE WITH assemblies
ENGINEERING STANDARD 19040 TO
ACHIEVE CLEANLINESS PER INSP. STD.
16599:
a. AT TIME OF ASSEMBLY: AS SPECIFIED

ON ITEM PRINT.
b. AFTER ASSEMBLY: EXTERNAL
SURFACES CLASS V, TEST METHOD I
Assembled fuel CLEANING, HANDLING & PRESERVATION Low pressure
system pump SHALL BE IN ACCORDANCE WITH ENGR. pump assemblies
product. STD. 19040 TO ACHIEVE CLEANLINESS PER
INSP. STD. 16599:
a. AFTER COMPLETING FUNCTIONAL
TEST: INTERNAL FUEL WETTED
SURFACES SHALL BE CLASS A, TEST
METHOD V, FOR A SAMPLE OF 1 LITER
OF FLUID COLLECTED WHILE THE
PUMP IS OPERATED AT A RATED
CONDITION.
Component where CLEANING, HANDLING & PRESERVATION Valve body,
only the internal SHALL BE IN ACCORDANCE WITH ENGR. various housings
surface area is to be STD. 19040 TO ACHIEVE CLEANLINESS PER with internal
evaluated which are INSP. STD. 16599: passageways.
marked on the part a. Internal surface area = Approx. xxxx mm2.
drawing. b. Internal surfaces Class A Test Method II.
c. External surfaces Class V Test Method I.

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Appendix B: General Requirements Test Environment/Equipment/Reagents
Testing requires an environment that would be satisfactory for operating high precision balances
and microscope. Components that are intended for testing shall be handled with forceps or lint-free
gloves. Cleanliness class level of parts for test shall be maintained prior to test and cross
contamination of groups of parts shall be avoided with plastic polyethylene bags of adequate size.
No paper products such as bags, box, towels, etc. shall be used in test lab environment. Room
Environment shall conform to at least class 8 level of cleanliness of airborne particles per
ISO 14644. Calibration of all measuring equipment should be performed on a periodic basis as per
quality control plan.

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Appendix B: General Requirements Test Environment/Equipment/Reagents (Continued)
Table B1: Equipment, Apparatus, and Reagent Requirements by Test Method
Applies to
Item
Test Method
a. Particle Counting System and software capable of reporting in the optional II
ISO 16232 format. Microscope capable of accurately detecting 6 or and III,
greater µm particles, adjustable lighting, high resolution, high speed IV, V,VI
motor stage, and other features, as needed, to determine/compare the
dimensions of particles with the limits of this specification. The
microscope should conform to the requirements of ISO 16232-7.
b. Analytical laboratory balance that can accurately weigh filter membranes II, III, IV,
in the expected range of weights with a percent error of less than or equal V,VI
to 10%.
c. Mechanical vacuum pump capable of maintaining a vacuum on the filter II, III, IV, V,
apparatus of 85 kPa/25 inches of mercury. VI
d. Drying oven capable of maintaining a temperature of 100 ºC II, III, IV,
(212 °F) minimum V,VI
e. Filter flask, not less than 0.5 L capacity. (Method II and III) II, III, IV,
V,VI
f. Filter holder for 47 mm Millipore filter membranes II, III, IV,
V,VI
g. Millipore 5 µm SMWP filter membrane when petroleum solvent or II, III, IV,
Envirosolve 655 is used as a rinsing liquid or 5 micron SVLP, TMTP V,VI
when Neutrapon/Neutracare 5088 is used as a rinsing liquid are the
recommended filter membranes usable for the test methods in this
standard. Nominal pore size of the filter membrane shall be smaller than
the smallest particle size to be counted/sized, see Section 3. Definitions
on page 3.
h. Glass slides or specially designed filter membrane holder to capture filter II, III, IV,
membranes for particle counting. V,VI

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Identifier
(ITEM)
Appendix B: General Requirements Test Environment/Equipment/Reagents (Continued)
Table B1: Equipment, Apparatus, and Reagent Requirements by Test Method (Continued)
Applies to
Item
Test Method
i. Stainless steel forceps and tweezers suitable for handling filter II, III, IV,
membranes and components. V,VI
j. Bench top ultrasonic cleaning equipment with a frequency of 30-50 kHz III
and a minimum power of 13 W/Liter.
k. Non-shedding bristle brush. The brush material shall not be detrimental to II
the surface of the part. The diameter of the brush material shall be a
minimum of 10 percent greater than the hole it is being used to clean.
l. Rinsing liquid shall be in accordance with the following: II, III, IV,
Petroleum Hydrocarbon V,VI
Surface tension is 18-22 mN/m at 25 °C (77 °F)
All metal safe
Specific gravity between 0.7-1.1 (water = 1) at 25 °C (77 °F)
Does not leave residue
Maximum of 0.1 mg of contamination per volume used for one test
Note: Envirosolv 655 or similar solvent is a recommended rinsing liquid
and can be purchased from Fine Organics Corporation. Reclaimed solvent
from vendors shall not be used. Alternatively Neutracare/Neutrapon 5088
can be used as rinsing liquid for Test Method IV and can be purchased
from Henkel Technologies.
m. Collection System (Stainless Steel Spray Funnel-Method IV and/or flow IV, V, VI
or functional test stands-Method V, and VI)
n. Clean rinsing media should be at least 2 or better contamination level II, III, IV, V,
numbers cleaner/better than the level indicated for the part/assembly to be VI
tested.

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Identifier
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Appendix C: Test Method I (Visual Examination)
C1. Sampling
Sampling for Test Method I shall be in accordance with the following: The minimum number of
parts for each test should be sufficient to provide a total applicable component surface area of
testing greater than or equal to 8000 mm2/80 cm2 for the test.
C2. Test Method

The part shall be evaluated visually at a minimum of 10X magnification, with sufficient
illumination (>800 lumens/m2).

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Appendix D: Test Method II (Flush and Brush with Gravimetric Analysis)
D1. Contaminant Extraction

D1.1. Rinsing liquid used in this test method shall be petroleum hydrocarbon as specified in
Table B1: Equipment, Apparatus, and Reagent Requirements by Test Method on page 23, item l.
Sampling for test Method II shall be in accordance with the following: The minimum number of
parts for each test should be sufficient to provide a total applicable component surface area of
testing greater than or equal to 8000 mm2/80 cm2 for the test. Only surfaces as specified on the
engineering drawing or in-process documentation shall be tested in accordance with this method.
Parts shall be individually flushed and brushed.
D1.2. A test filter membrane shall be dried for 1 hour at 66 °C ± 3 °C (151 °F ± 5 °F) and pre-
weighed prior to filtering collected rinsing liquid. The surface as shown on the engineering
drawing or in-process documentation shall be flushed, brushed and rinsed at least twice with
rinsing liquid. Rinsing liquid shall be collected in a clean sampling tray, beaker or the like.
Collected rinsing liquid with debris shall be filtered through the dried filter membrane.
D1.3. Upon extraction of debris, the membrane shall be prepared according to the
requirements in Appendix I: Filter Membrane Preparation on page 32, and analyzed according to
the requirements in Appendix J: Filter Membrane Analysis on page 33.

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Identifier
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Appendix E: Test Method III (Ultrasonic with Gravimetric Analysis)
E1. Contaminant Extraction

E1.1. Rinsing liquid used in this test method shall be petroleum hydrocarbon as specified in
Table B1: Equipment, Apparatus, and Reagent Requirements by Test Method on page 23, item l.
If test samples have an oil based rust preventative fluid applied prior to cleanliness testing per test
method III, the preferred hydrocarbon solvent to use for contaminant extraction would be hexane.
The minimum number of parts for each test should be sufficient to provide a total applicable
component surface area of testing greater than or equal to 8000 mm2/80 cm2 for the test. All
beakers used for the extraction test should be cleaned to an acceptable level. Parts shall be equally
spaced within the beaker.
E1.2. Parts shall be fully immersed in rinsing liquid inside a beaker within bench top ultrasonic
cleaning equipment with a frequency of 30-50 kHz and a power level of 13 W/liter as specified in
Table B1: Equipment, Apparatus, and Reagent Requirements by Test Method on page 23. The
level of the liquid in the ultrasonic equipment shall not be lower than the level of the solvent within
the beaker containing the parts. The following parameters shall be controlled during this process:
a. Time: not less than 10 minutes.

b. Temperature: 21 to 32 ºC (70 to 90 ºF).
E1.3. Upon completion of ultrasonic cleaning, tested parts should additionally be rinsed for a
few seconds with standard laboratory squirt bottle with additional rinsing liquid into the beaker.
E1.4. A test filter membrane shall be dried for 1 hour at 66 °C +/-3 °C (151 °F ± 5 °F) and pre-
weighed prior to filtering collected rinsing liquid. Rinsing liquid shall be collected in a clean
sampling tray, beaker or the like. Collected rinsing liquid with debris shall be filtered through the
dried filter membrane. Upon extraction of debris, the filter membrane shall be prepared according
to the requirements in Appendix I: Filter Membrane Preparation on page 32, and analyzed
according to the requirements in Appendix J: Filter Membrane Analysis on page 33.

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Identifier
(ITEM)
Appendix F: Test Method IV (Pressurized Spray with Particle Counting)
Note: The primary use of Test Method IV is to measure the cleanliness of components and the
results are normally expressed in particles per a given surface area.
F1. Contaminant Extraction

F1.1. Rinsing liquid used in this test method can either be Neutracare/Neutrapon 5088 or a
petroleum hydrocarbon solvent according to Table B1: Equipment, Apparatus, and Reagent
Requirements by Test Method on page 23, item l. To perform this test method a spray funnel as
described in Table B1: Equipment, Apparatus, and Reagent Requirements by Test Method on page
23, item m. is required. The minimum number of parts for each test shall be sufficient to provide a
total part area of testing exceeding 8000 mm2/80 cm2. If the rinsed debris on filter membrane is
too numerous such that particles overlay and touch one another, surface area needs to be reduced.
The overloaded membrane shall be discarded and a new membrane shall be generated using a
lesser amount of parts/surface area deemed appropriate.
F1.2. Background cleanliness of the rinsing liquid and collection system shall be determined,
documented, and controlled. Prior to any evaluations, the funnel shall be rinsed at the start of shift
or after 2 hours of idle time. Background contamination should be kept to a level consistent
acceptable level according to what is stated in ISO 16232-3 Section 6.
F1.3. The calculated flow rate from the rinsing nozzle shall be 4L/minute +/- 10%. The rinsing
liquid spraying pressure at the 3 millimeter diameter spray gun exit orifice shall be 207 +/- 69 kPa
(30 +/- 10 psi). The operating conditions of the spray system shall be maintained and monitored
periodically to assure a consistent (i.e., +/- 10%) rate of flow from the exit orifice of the spray gun.
The rate of flow (i.e., L/min) from the exit orifice of the spray gun shall be determined,
documented, and monitored. The rate of flow from the exit orifice of the spray gun shall be re-
determined/re-verified prior to use whenever there are changes to the spray system (i.e., new or
replacement hoses, orifice pump, spray gun, filters in the spray system). The minimum spraying
time per part shall be sufficient to deliver a minimum of 0.11 mL/mm2 to the part surfaces. If
multiple parts are required to make the minimum surface area requirement of 8000 mm2/80 cm2
the calculated spray time shall be split evenly between all parts used in the test.
F1.4. The filter membrane (refer to Table B1: Equipment, Apparatus, and Reagent
Requirements by Test Method on page 23, item g.) used for the particle/debris collection shall be
documented and controlled.

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Identifier
(ITEM)
Appendix F: Test Method IV (Pressurized Spray with Particle Counting) (Continued)
F1.5. The suction pump below the collection system filter holder should be set to minimize
“ponding” of rinsing liquid above the filter patch on the spray funnel.
F1.6. Parts shall be individually sprayed. However, it is permissible to have all of the parts for
the individual test in the funnel at the same time. After individually spraying the part(s) for the
required individual time(s), completely spray the inside of the funnel (and any internal funnel
fixture) and part(s) for a sufficient amount of time as to wash the liberated debris from the part(s)
down into the collection filter membrane.
F1.7. Upon extraction of debris, the membrane shall be prepared according to the requirements
in Appendix I: Filter Membrane Preparation on page 32, and analyzed according to the
requirements in Appendix J: Filter Membrane Analysis on page 33.

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Identifier
(ITEM)
Appendix G: Test Method V (Internally Flowed Assembly with Particle Counting)
Note: The primary use of Test Method V is to measure the cleanliness of an assembly that has
internal mechanics that can generate its own fluid pressure/flow i.e., high pressure pumps, low
pressure pumps. this test method shall be used to measure the cleanliness of the fluid which is
expelled from a fuel pump.
G1. Contaminant Extraction

G1.1. The test piece/assembly should be loaded onto the functional test stand and run through
the normal test cycle sequence. During this cycle debris will be liberated from the test piece. To
accurately assess the cleanliness of the test piece/assembly fluid should be collected. The fluid
sampling for test method V shall be in accordance with the following: The fluid volume collected
for the test shall be 500 mL +/- 25 mL. The collection fluid shall be obtained at or near the end of
the performance test cycle. The collection point of the fluid shall be as close to the outlet of the test
piece as can be safely sampled. A clean container shall be used for collection of the fluid.
G1.2. The fluid sample pulled directly from the test stand shall be collected in a clean sampling
tray, beaker or the like. Collected rinsing liquid with debris shall be filtered through the filter
liquid. The filter liquid (refer to Table B1: Equipment, Apparatus, and Reagent Requirements by
Test Method on page 23, item g.) used for the particle/debris collection shall be documented and
controlled.
G1.3. Upon extraction of debris, the membrane shall be prepared according to the

162023-056 012 Page 30 of 34
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Identifier
(ITEM)
Appendix H: Test Method VI (Internally Flowed Component with Particle Counting)
Note: The primary use of Test Method VI is to measure the internal cleanliness of components. The
results are typically expressed as particles per a given internal volume of the part. Examples: Fuel
lines, accumulators, fuel filters etc.
H1. Contaminant Extraction

H1.1. Rinsing liquid used in this test method can either be Neutracare/Neutropon 5088 or
petroleum hydrocarbon according to Table B1: Equipment, Apparatus, and Reagent Requirements
by Test Method on page 23, item l. To perform test method VI typically a test stand with pumping
capabilities to deliver clean fluid at rated/nominal flow of the test piece is a requirement. The filter
membrane (refer to Table B1: Equipment, Apparatus, and Reagent Requirements by Test Method
on page 23, item g.) used for the particle/debris collection shall be documented and controlled.
H1.2. The preferred test method is to use in line collection thru membrane holder. (ISO 16232-
4 and 5.1.3 a) This method allows for contaminant collection without having to handle fluid
containers and conduct the filtration process under vacuum.
H1.3. An alternative method (ISO 16232-4 and 5.1.3 b) is to collect the liquid at the outlet of
the filter under test in a clean container and filter it on membrane(s) using a vacuum pump. The
extraction fluid shall be filtered on a filter membrane as specified in Table B1: Equipment,
Apparatus, and Reagent Requirements by Test Method on page 23, item g. using vacuum pump
and vacuum flask. Great care should be taken in that the collection container should be clean prior
sampling the fluid.
H1.4. Sampling for Test Method VI shall be in accordance with the following: The appropriate
fluid volume collected during particle extraction shall be determined by performing an extraction
validation procedure as stated in ISO 16232-5, Section 6.2 Extraction Procedure Setup and
Validation. Once the appropriate parameters have been established, they can be used for future
testing of that part. The flow rate during contaminant extraction should be set at the rated/nominal
flow of the test piece as stated on the individual part print.
H1.5. Upon extraction of debris, the membrane shall be prepared according to the

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Identifier
(ITEM)
Appendix I: Filter Membrane Preparation
If particle counting is to be performed as in methods IV, V, and VI no pre-drying of the filter

membrane is necessary. The whole volume of the rinsing media plus extracted contaminant shall
be filtered through a filter membrane as specified in Table B1: Equipment, Apparatus, and Reagent
Requirements by Test Method on page 23, item g.
The membrane(s) shall be dried for 1 hour, preferably in an oven, as specified in Table B1:
Equipment, Apparatus, and Reagent Requirements by Test Method on page 23, item d. and
weighed. The filter membrane shall be dried again for at least again 15 minutes and weighed again
until two successive weight readings are within +/-5% of each other. Drying temperature and time
should be documented in the test report.

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Identifier
(ITEM)
Appendix J: Filter Membrane Analysis
After filter membrane preparation, if gravimetric analysis of the filter membrane is being
performed as required by methods II and III, record the weight measurement using an analytical
balance as specified in Table B1: Equipment, Apparatus, and Reagent Requirements by Test
Method on page 23. The length and width of the largest metallic and non-metallic particle shall be
recorded in micrometers and checked against the appropriate cleanliness class in the table.
Acceptance Criteria for Gravimetric Test Methods in Section 4.3. Acceptance Criteria by Test
Method on page 10. Debris type shall be noted, i.e., metal shavings, metal fines, fibers or plastics.
If particle counting analysis will be performed as required by test methods IV, V, and VI, the filter
membrane will need to be flattened out as much as possible in preparation for microscopic particle
counting analysis. Some common ways to achieve this are to: 1. Sandwich the membrane between
two clean glass slides and tape together, or 2. Load membrane onto an appropriately designed filter
membrane holder which can be loaded onto the microscope. Option 1 is the preferred method in
this case.
The sizes and numbers of particles on the filter membrane shall be measured and counted using the
particle counting system specified in Table B1: Equipment, Apparatus, and Reagent Requirements
by Test Method on page 23, item a. for every particle size category given in the specified
cleanliness class level requirement.
If the rinsed debris on filter membrane are too numerous such that particles overlay and touch one
another, the overloaded filter membrane shall be discarded and a set of new filter membranes shall
be generated.
Extraction fluid should be filtered using several membranes and counts added together.
If the class AA requirements are specified on the part print of the test piece an additional step shall
be completed. The microscope should be set to incidental (top down) lighting. Visual examination
shall be performed over the entire filter membrane of particles in the size range of “class AA hard
particles” as stated the acceptance criteria in Section 4.3. Acceptance Criteria by Test Method on
page 10. The number of hard particles should be determined and reported within the specified size
range. Optionally the magnification can be increased for better particle recognition. See
Examination of hard particles Section 4.4. Properties of Hard Particles on page 13.
After analysis, the filter membranes shall be preserved in a manner that permits recounting for a
period of time approved by the Cummins SQI Organization or manufacturing plant quality
organization.

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(ITEM)
Appendix K: Reporting of Results
The test report/log/worksheet shall include (but not be limited to):
a. Identification of the inspector

b. Location of inspection
c. Inspection date
d. Part Number
e. Parts/Sample Identifier (Something unique about this sample, i.e., lot/batch number, serial
number, etc.)
f. Part noun name
g. Area (mm2) per part (Method II, III, IV)
h. Volume (mm3) of test piece (Method VI)
i. Number of pieces/parts checked
j. Residual magnetism level(s) prior to inspection
k. Net weight of debris (gravimetric analysis method only)
l. Raw Count/Size data: 1. Per part area for methods II, III, IV or 2. Per volume for method
VI.
m. Calculated number of particles per 1000 cm2 or 100 cm3/mL for each size range.
n. Comments on conformance
o. Cleanliness Class Level
All reports shall be saved and archived electronically and/or by hard copy per the time period
specified by facility’s Quality System requirements.

162023-056 012 Page 34 of 34

012 Cleanliness

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012 Cleanliness

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Engineering

INSPECTION SPECIFICATON 16599

Current Release Number Std. Revision Level

INSPECTION SPECIFICATON 16599

Heading Page Number

Current Release Number Std. Revision Level

INSPECTION SPECIFICATON 16599

a. CES 10054, Standards Organizations Addresses

3.1. As Received from Supplier

3.3. At Point of Assembly

At point of assembly refers to components to be assembled at the point of assembly.

Current Release Number Std. Revision Level

INSPECTION SPECIFICATON 16599

3.4. Cleanliness Class Level

3.5. Cognizant Engineering Organization

3.6. Cognizant Quality Organization

3.7. Collection System

3.8. Contamination Level

3.10. Hard Particle/Debris

Current Release Number Std. Revision Level

INSPECTION SPECIFICATON 16599

3.11. Membrane Filter

3.13. Particle Counting System

3.14. Rinsing Liquid

Current Release Number Std. Revision Level

INSPECTION SPECIFICATON 16599

a. Cleanliness Class Level of the component

Current Release Number Std. Revision Level

INSPECTION SPECIFICATON 16599

4.2. General Rules for Cleanliness Testing

(All Test Methods except Test Method I)

4.2.1. The general testing procedure consists of the following steps:

4.2.2. General Condition of Cleanliness-All Classes

Current Release Number Std. Revision Level

INSPECTION SPECIFICATON 16599

4.2.3. Class Cleanliness Requirements

Size Class Size X (m)

Current Release Number Std. Revision Level

INSPECTION SPECIFICATON 16599

Table 2: Definition of Contamination Level

Taken from ISO 16232-10 (2007 Edition)

Current Release Number Std. Revision Level

INSPECTION SPECIFICATON 16599

Table 2: Definition of Contamination Level (Continued)

64 x 103 130 x 103 17

130 x 103 250 x 103 18

250 x 103 500 x 103 19

500 x 103 1 x 106 20

Taken from ISO 16232-10 (2007 Edition)

4.3. Acceptance Criteria by Test Method

4.3.1. Test Method I-Visual Inspection

(Appendix C: Test Method I (Visual Examination) on page 25)

Current Release Number Std. Revision Level

INSPECTION SPECIFICATON 16599

Maximum Allowed Maximum

Class B 0.0002 mg/mm2 625x375 micrometers 6.5 mg

Class A 0.0001 mg/mm2 250x125 micrometers 6.5 mg

Class AA 0.00005 mg/mm2 250x125 micrometers 4.0 mg

Examples using the acceptance criteria:

Current Release Number Std. Revision Level

INSPECTION SPECIFICATON 16599

Table 4: Cleanliness Class Level Defined by Contamination Level/Size Range

Current Release Number Std. Revision Level