ISO/DIS 12345

Diesel engines -- Cleanliness assessment of fuel injection equipment

Moteurs diesels -- Évaluation de propreté pour équipement d'injection de combustible

Standards Content (sample)

DRAFT INTERNATIONAL STANDARD
ISO/DIS 12345
ISO/TC 22/SC 34 Secretariat: ANSI
Voting begins on: Voting terminates on:
2020-04-28 2020-07-21
Diesel engines — Cleanliness assessment of fuel injection
equipment

Moteurs diesels — Évaluation de propreté pour équipement d'injection de combustible

ICS: 43.060.40
THIS DOCUMENT IS A DRAFT CIRCULATED
FOR COMMENT AND APPROVAL. IT IS
THEREFORE SUBJECT TO CHANGE AND MAY
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STANDARD UNTIL PUBLISHED AS SUCH.
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ISO/DIS 12345:2020(E)
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NOTIFICATION OF ANY RELEVANT PATENT
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PROVIDE SUPPORTING DOCUMENTATION. ISO 2020
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ISO/DIS 12345:2020(E)
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ISO/DIS 12345:2020(E)
Contents Page

Foreword ..........................................................................................................................................................................................................................................v

Introduction ................................................................................................................................................................................................................................vi

1 Scope ................................................................................................................................................................................................................................. 1

2 Normative references ...................................................................................................................................................................................... 1

3 Terms and definitions ..................................................................................................................................................................................... 1

4 Test apparatus ......................................................................................................................................................................................................... 2

4.1 General ........................................................................................................................................................................................................... 2

4.2 Pressure source ...................................................................................................................................................................................... 2

4.2.1 General...................................................................................................................................................................................... 2

4.2.2 Fuel injection pump test bench ........................................................................................................................... 2

4.2.3 Hand-lever-operated testing and setting apparatus ......................................................................... 2

4.2.4 High-pressure pulsating flow rig ....................................................................................................................... 2

4.2.5 Verification low pressure pump ......................................................................................................................... 2

4.2.6 Verification high pressure delivery pump .................................................................................................. 3

4.2.7 Pressure vessel .................................................................................................................................................................. 3

4.2.8 Flushing pump ................................................................................................................................................................... 3

4.3 V erification high-pressure pipe assembly ....................................................................................................................... 3

4.4 V erification test injector.................................................................................................................................................................. 3

4.5 Collecting vessel ..................................................................................................................................................................................... 3

4.6 V erification rail ....................................................................................................................................................................................... 3

4.7 Equipment for contamination measurement ............................................................................................................... 4

4.7.1 General...................................................................................................................................................................................... 4

4.7.2 Gravimetric analysis apparatus........................................................................................................................... 4

4.7.3 Microscopic analysis apparatus .......................................................................................................................... 5

4.8 Test fluid ....................................................................................................................................................................................................... 5

4.8.1 General...................................................................................................................................................................................... 5

4.8.2 Calibration fluid ................................................................................................................................................................ 6

4.8.3 Solvent, aliphatic hydrocarbon ............................................................................................................................ 6

4.8.4 Water, de-mineralised ................................................................................................................................................. 6

4.9 Clean-up filter .......................................................................................................................................................................................... 6

4.10 Pressure gauge ........................................................................................................................................................................................ 6

5 Procedure..................................................................................................................................................................................................................... 6

5.1 General ........................................................................................................................................................................................................... 6

5.2 High-pressure supply pumps (common rail fuel injection system) .......................................................... 7

5.2.1 General...................................................................................................................................................................................... 7

5.2.2 Dynamic test with the test pump running ................................................................................................. 7

5.2.3 Flushing test at low speed with the test pump running by hand ........................................... 8

5.3 Unit injectors ............................................................................................................................................................................................ 9

5.3.1 General...................................................................................................................................................................................... 9

5.3.2 Equipment set up and verification of cleanliness ............................................................................... 9

5.3.3 Test procedure ................................................................................................................................................................... 9

5.4 Fuel injection pumps ......................................................................................................................................................................... 9

5.4.1 General...................................................................................................................................................................................... 9

5.4.2 Equipment set up and verification of cleanliness ............................................................................... 9

5.4.3 Test procedure ................................................................................................................................................................10

5.5 CR fuel injectors ..................................................................................................................................................................................10

5.5.1 General...................................................................................................................................................................................10

5.5.2 Dynamic test .....................................................................................................................................................................10

5.5.3 Continuous high-pressure flow test .............................................................................................................11

5.6 Fuel injectors (Nozzle holder assemblies) ...................................................................................................................12

5.6.1 General...................................................................................................................................................................................12

5.6.2 Dynamic test .....................................................................................................................................................................12

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ISO/DIS 12345:2020(E)

5.6.3 Syringe test (washing out injectors) ............................................................................................................13

5.7 High-pressure fuel injection pipes ......................................................................................................................................13

5.7.1 General...................................................................................................................................................................................13

5.7.2 Dynamic test .....................................................................................................................................................................13

5.7.3 High-pressure flushing test .................................................................................................................................14

5.7.4 Syringe (solvent dispenser) or hand flush test ...................................................................................15

5.8 Rails ...............................................................................................................................................................................................................15

5.8.1 General...................................................................................................................................................................................15

5.8.2 Pressure vessel flushing test...............................................................................................................................15

5.8.3 Low pressure flushing test ...................................................................................................................................17

5.8.4 Syringe or hand flush test .....................................................................................................................................18

5.9 Low-pressure systems ...................................................................................................................................................................19

5.9.1 General...................................................................................................................................................................................19

5.9.2 Equipment set up and verification of cleanliness ............................................................................19

5.9.3 Test procedure ................................................................................................................................................................19

6 Sample analysis ...................................................................................................................................................................................................19

6.1 General ........................................................................................................................................................................................................19

6.2 Gravimetric analysis ........................................................................................................................................................................19

6.3 Particle size distribution .............................................................................................................................................................20

6.3.1 Expression of results .................................................................................................................................................20

7 Reporting of the inspection results ................................................................................................................................................20

8 Designation of cleanliness requirements ................................................................................................................................20

Annex A (informative) Typical test equipment for measuring fuel injection equipment

cleanliness ................................................................................................................................................................................................................21

Annex B (informative) Rail low pressure flushing test ...................................................................................................................28

Annex C (informative) Procedure for verifying test equipment initial cleanliness ..........................................30

Annex D (informative) Determination of flushing parameters for rail pressure vessel

flushing test ............................................................................................................................................................................................................33

Annex E (informative) Comparison of CCC (Component Cleanliness Code, ISO 16232) to

FIECC (Fuel Injection Equipment Cleanliness Code, ISO 12345:2013) .....................................................35

Bibliography .............................................................................................................................................................................................................................37

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ISO/DIS 12345:2020(E)
Foreword

ISO (the International Organization for Standardization) is a worldwide federation of national standards

bodies (ISO member bodies). The work of preparing International Standards is normally carried out

through ISO technical committees. Each member body interested in a subject for which a technical

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ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of

electrotechnical standardization.

The procedures used to develop this document and those intended for its further maintenance are

described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the

different types of ISO documents should be noted. This document was drafted in accordance with the

editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).

Attention is drawn to the possibility that some of the elements of this document may be the subject of

patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of

any patent rights identified during the development of the document will be in the Introduction and/or

on the ISO list of patent declarations received (see www .iso .org/ patents).

Any trade name used in this document is information given for the convenience of users and does not

constitute an endorsement.

For an explanation on the voluntary nature of standards, the meaning of ISO specific terms and

expressions related to conformity assessment, as well as information about ISO's adherence to the

World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see the following

URL: www .iso .org/ iso/ foreword .html.

This document was prepared by Technical Committee ISO/TC22, Road vehicles, Subcommittee SC 34,

Propulsion, powertrain, and powertrain fluids.

This second edition cancels and replaces the first edition (ISO 12345:2013), which has been technically

revised.

The changes in this 2 edition are related to the change of ISO 16232 Part 1 – 10 to ISO 16232:2018.

The reporting of the inspection results (clause 7) changed therefore from FIECC (Fuel Injection

Equipment Cleanliness Code, as in ISO 12345:2013) to CCC (Component Cleanliness Code, as in

ISO 16232). As ISO 16232 gained in worldwide use, it does no longer make sense for the Fuel Injection

Equipment Industry to have a separate coding.
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ISO/DIS 12345:2020(E)
Introduction

Modern fuel injection systems contain many closely controlled clearances and rely on the fuel-flowing

characteristics of small orifices; thus they require the close control of sources of contamination in

order to maintain the operational performance demanded of them throughout their design life. To this

end, such systems are designed with integral fuel-filtration equipment, which reduces the amount of

potentially damaging debris that could enter the system from external sources.

However, contamination of the fuel injection system can also occur internally, from system use or

wear, from equipment servicing, or as a result of the original supplier’s manufacturing and assembly

processes. The focus of this International Standard is on the latter source of contamination, and is thus

concerned with the assessment of the cleanliness of the fuel injection equipment as originally supplied

to the engine manufacturer.

Fuel injection systems comprise a number of components. Traditional systems contain low pressure

elements (fuel tank, pipe-work, filters, lift pump, etc.), a fuel injection pump, high-pressure pipes and

fuel injectors, located within the engine cylinder head.

During the preparation of this International Standard, the importance of care in the handling and

measurement of contamination samples was clearly recognized. Moreover, the low levels of contaminant

with fuel injection equipment makes this a particularly difficult task. For this International Standard to

be used meaningfully - as an indicator of component cleanliness and a driver towards higher quality

standards - extreme attention to detail is required of the user. Verification requirements for the test

equipment used are therefore emphasized, in detail.

It is not always clear what level and type of cleanliness would be beneficial for improved performance

and life on a cost-effective basis. The actual quantitative levels can only be set in relation to other

parameters, agreed between the manufacturer, supplier and user. This International Standard provides

a set of procedures for evaluating the cleanliness of fuel injection equipment and a framework for a

common measurement and reporting.
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DRAFT INTERNATIONAL STANDARD ISO/DIS 12345:2020(E)
Diesel engines — Cleanliness assessment of fuel injection
equipment
1 Scope

This International Standard specifies cleanliness assessment procedures for evaluating the amount of

debris found within the clean side of diesel fuel injection assemblies, which could lead to a reduction in

the system’s operational effectiveness.

While other International Standards, e.g. ISO 16232, relate to cleanliness of components used in road

vehicle fluid circuits, this International Standard is focused on diesel fuel injection assemblies as

supplied to diesel engine manufacturers or the service market.
2 Normative references

The following documents, in whole or in part, are normatively referenced in this document and are

indispensable for its application. For dated references, only the edition cited applies. For undated

references, the latest edition of the referenced document (including any amendments) applies.

ISO 3722, Hydraulic fluid power — Fluid sample containers — Qualifying and controlling cleaning methods

ISO 4008-1, Road vehicles — Fuel injection pump testing — Part 1: Dynamic conditions

ISO 4113, Road vehicles — Calibration fluids for diesel injection equipment
ISO 4788, Laboratory glassware — Graduated measuring cylinders

ISO 7440-1, Road vehicles — Fuel injection equipment testing — Part 1: Calibrating nozzle and holder

assemblies

ISO 8535-1, Diesel engines — Steel tubes for high-pressure fuel injection pipes — Part 1: Requirements for

seamless cold-drawn single-wall tubes

ISO 8984-1, Diesel engines — Testing of fuel injectors — Part 1: Hand-lever-operated testing and setting

apparatus

ISO 14644-1, Cleanrooms and associated controlled environments — Part 1: Classification of air cleanliness

by particle concentration
ISO 16232:2018, Road vehicles — Cleanliness of components and systems
3 Terms and definitions

For the purposes of this document, the terms and definitions given in ISO 16232, clause 3 and the

following apply.

ISO and IEC maintain terminological databases for use in standardization at the following addresses:

• ISO Online browsing platform: available at https:// www .iso .org/ obp
• IEC Electropedia: available at http:// www .electropedia .org/
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ISO/DIS 12345:2020(E)
3.1
Reynolds number

dimensionless parameter expressing the ratio between the inertia and viscous forces in a flowing fluid,

given by the formula
Ul×
Re=
where

U is the mean axial fluid velocity across the defined area, expressed in millimetres per seconds

l is the characteristic dimension of the system over which the flow occurs, expressed in mil-

limetres
[for pipes l = d (pipe bore diameter)]

ν is the kinematic viscosity of the fluid, expressed in square millimetres per second (centistokes).

4 Test apparatus
4.1 General

Typical test equipment recommended for measuring fuel-injection equipment cleanliness are described

in Annex A. Following are details of specific apparatus that shall be used, unless a suitable alternative

can be demonstrated.
4.2 Pressure source
4.2.1 General
The pressure source is test dependent as described in the following subclauses.
4.2.2 Fuel injection pump test bench

A test bench as specified in ISO 4008-1 with a single cylinder pump or one cylinder of an inline pump

4.2.3 Hand-lever-operated testing and setting apparatus
A testing apparatus as described in ISO 8984-1.
4.2.4 High-pressure pulsating flow rig
A pressure source capable of achieving

a) a flow rate which will generate a turbulent flow in the pipes (Re > 4000) for a period of 30 s ± 1 s,

while pulsating the flow between zero and this value at a frequency of 0,2 Hz to 1 Hz, followed by

b) a flush at 1,4 MPa ± 0,1 MPa constant pressure for 15 s ± 1 s.
4.2.5 Verification low pressure pump

A plunger or diaphragm-type pump having a flow rate of approximately twice the rated value for the

component under test at a pressure of at least 2 MPa.

The verification low-pressure pump shall be cleaned to the cleanliness level CL in accordance with

Annex C and carefully stored with proper cover in a clean environment.
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ISO/DIS 12345:2020(E)
4.2.6 Verification high pressure delivery pump

For testing of high-pressure pipes with open ends, having a flow rate capable of generating a Reynolds

number in the pipes of Re > 4000. A pressure capability of 3 MPa ± 0,1 MPa is considered suitable.

The verification high-pressure delivery pump shall be cleaned to the cleanliness level CL in accordance

with Annex C and carefully stored with proper cover in a clean environment.
4.2.7 Pressure vessel

Used as pressure source, shall be able to supply a testing pressure of at least 0,5 Mpa ( = 5 bar) and to

produce a turbulent flow inside the rail (recommended flow rate at least 2,5 l/min).

4.2.8 Flushing pump

For testing of rails with open ends, having a flow rate of at least 0,1 l/min. For this pump a pressure

capability of up to 0,1 MPa ± 0,01 MPa is considered suitable.
4.3 Verification high-pressure pipe assembly

600 mm long, of tube ISO 8535-1 S-2-6-2 1 P 0, as specified in ISO 8535-1 , and suitable for the

component under test.

Stainless steel tubing should be used because of its resistance to rust and corrosion contamination. The

verification high-pressure pipe assembly shall be cleaned to the cleanliness level CL in accordance with

Annex C and carefully stored with proper cover in a clean environment.
4.4 Verification test injector

In accordance with ISO 7440-1, fitted with an orifice plate of orifice diameter 2,5 mm.

The inlet edge filter shall be removed to improve the particle passage. The nozzle opening pressure

+03,
shall be set to 20,7 MPa.
4.5 Collecting vessel

Which may be necessary for collecting test fluid downstream from the tested equipment at a flow

rate different from that passing through the particle counter, the contamination monitor or the

membrane filter.

The collecting vessel may be used for storing test fluid before transfer fluid samples to laboratory

for analysis. A cylindrical stainless steel or glass reservoir with a conical bottom should be used for

facilitating further particle collection.
4.6 Verification rail

Needed to establish the cleanliness level CL for the whole rail cleanliness test apparatus.

For the verification the verification rail shall be cleaned to the blank value in accordance with Annex C

and carefully stored with proper cover in a clean environment.

1) Use of stainless steel tubing is recommended to resist rust and corrosion contamination

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ISO/DIS 12345:2020(E)
4.7 Equipment for contamination measurement
4.7.1 General

Involving the application of two specific techniques for evaluating the level of contamination:

— gravimetric analysis;
— microscopic examination.
Each requires the specific laboratory apparatus as given in 4.7.2 to 4.7.3.
4.7.2 Gravimetric analysis apparatus
NOTE For gravimetric analysis see ISO 16232 Clause 9.2.2.
4.7.2.1 Non-ventilated drying oven
Capable of maintaining a temperature of 80 °C ± 2 °C.
4.7.2.2 Filter holder
Comprising

— glass funnel of at least 300 ml capacity with suitably calibrated volumetric graduations (e.g. 25 ml

± 2 ml),
— suitable cover for the funnel (e.g. petri dish),
— clamping device,
— suitable base to support the membrane filter, and

— a means of dissipating any static electricity generated during the filtering process.

4.7.2.3 Vacuum flask
Suitable for the fil
...