ISO 12345:2013

INTERNATIONAL ISO
STANDARD 12345
Second edition
2013-03-15
Corrected version
2014-05-15
Diesel engines — Cleanliness
assessment of fuel injection
equipment
Moteurs diesels — Évaluation de propreté pour équipement
d’injection de combustible
Reference number
ISO 12345:2013(E)
©
ISO 2013

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ISO 12345:2013(E)

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© ISO 2013
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized otherwise in any form
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ISO 12345:2013(E)

Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Test apparatus . 3
4.1 General . 3
4.2 Pressure source . 3
4.3 Verification high-pressure pipe assembly . 4
4.4 Verification test injector. 4
4.5 Collecting vessel . 4
4.6 Verification rail . 4
4.7 Equipment for contamination measurement . 4
4.8 Test fluid . 6
4.9 Clean-up filter . 7
4.10 Pressure gauge . 7
5 Procedure. 7
5.1 General . 7
5.2 High-pressure supply pumps (common rail fuel injection system) . 8
5.3 Unit injectors . 9
5.4 Fuel injection pumps .10
5.5 CR fuel injectors .11
5.6 Fuel injectors (Nozzle holder assemblies) .13
5.7 High-pressure fuel injection pipes .14
5.8 Rails .16
5.9 Low-pressure systems .19
6 Sample analysis .20
6.1 General .20
6.2 Gravimetric analysis .20
6.3 Particle size distribution .20
6.4 Largest particle size .20
7 Reporting results .21
7.1 Principle of fuel injection equipment cleanliness code .21
7.2 Examples of fuel injection equipment cleanliness code usage .22
8 Designation .23
Annex A (informative) Typical test equipment for measuring fuel injection
equipment cleanliness .24
Annex B (informative) Rail low pressure flushing test .31
Annex C (informative) Procedure for verifying test equipment initial cleanliness .33
Annex D (informative) Determination of flushing parameters for rail pressure vessel
flushing test .35
Bibliography .37
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ISO 12345:2013(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
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International
Standards adopted by the technical committees are circulated to the member bodies for voting.
Publication as an International Standard requires approval by at least 75 % of the member bodies
casting a vote.
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.
ISO 12345 was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 7, Injection
equipment and filters for use on road vehicles.
This second edition cancels and replaces the first edition (ISO 12345:2002), which has been technically
revised.
This corrected version of ISO 12345:2013 incorporates the following corrections.
5.9.1: The second paragraph is replaced by the following:
Cleanliness of the clean side of fuel filters is already covered by ISO 4020 and is not detailed in this
International Standard, although the procedures should be compatible. The extraction method from
ISO 4020 may be used, however, the FIECC according to Clause 7 shall be used for reporting results.
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ISO 12345:2013(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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INTERNATIONAL STANDARD ISO 12345:2013(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. the ISO 16232 series, 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 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 16232-5, Road vehicles — Cleanliness of components of fluid circuits — Part 5: Method of extraction of
contaminants on functional test bench
ISO 16232-6, Road vehicles — Cleanliness of components of fluid circuits — Part 6: Particle mass
determination by gravimetric analysis
ISO 16232-7, Road vehicles — Cleanliness of components of fluid circuits — Part 7: Particle sizing and
counting by microscopic analysis
ISO 16232-9, Road vehicles — Cleanliness of components of fluid circuits — Part 9: Particle sizing and
counting by automatic light extinction particle counter
SAE J 1549, Diesel fuel injection pump — Validation of calibrating nozzle holder assemblies
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
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ISO 12345:2013(E)

3.1
fuel injection equipment cleanliness code
FIECC
alpha-numeric code representing the distribution of particles by size and/or weight
3.2
cleanliness level
CL
amount and/or nature of contaminant present on the controlled surfaces and/or in controlled volumes
of a component
Note 1 to entry: The term can apply to the presumed, specified or measured extent of contamination.
3.3
cleanliness specification
CS
document that specifies the cleanliness level CL required for a given component along with the agreed
inspection method
3.4
reynolds number
Re
dimensionless parameter expressing the ratio between the inertia and viscous forces in a flowing fluid,
given by the formula
Ul×
Re=
v
where
U is the mean axial fluid velocity across the defined area, expressed in millimetres per sec-
onds
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 (cen-
tistokes).
3.5
blank test
analysis carried out with the same operating conditions as on the test component but without the
component or the component being a “clean” master sample used only for this purpose
Note 1 to entry: The blank test allows quantification of the contamination brought in from the environment,
process or materials used.
3.6
blank value/ level
result obtained from the blank test
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ISO 12345:2013(E)

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 single cylinder inline pump as specified in SAE J1549 and a test bench as specified in ISO 4008-1.
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.
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.
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ISO 12345:2013(E)

4.3 Verification high-pressure pipe assembly
1)
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, while the pintle end may be removed to improve the particle
+03,
passage. The nozzle opening pressure shall be set to 20,7 MPa.
−0
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.
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 16232-6.
4.7.2.1 Non-ventilated drying oven
Capable of maintaining a temperature of 80 °C ± 2 °C.
1) Use of stainless steel tubing is recommended to resist rust and corrosion contamination.
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ISO 12345:2013(E)

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 filter holder and of capacity enabling it to hold the entire volume of sample liquid without
refilling.
4.7.2.4 Vacuum device
Able to generate a vacuum of 86,6 kPa (gauge).
4.7.2.5 Solvent dispenser (syringe)
A pressurized vessel that discharges solvent through an in-line filter membrane with a pore size of not
greater than 1 µm.
4.7.2.6 Tweezers
Flat-bladed (non-serrated, blunt tips), and of stainless steel.
4.7.2.7 Graduated cylinders
For measuring out the volume of test liquid, the accuracy of which shall be in accordance with ISO 4788,
unless a suitable alternative can be demonstrated (with a minimum accuracy of + 2%).
4.7.2.8 Sample bottles
Of 250 ml nominal capacity, preferably flat-bottomed and wide-mouthed, with a screw cap containing a
suitable internal polymeric seal.
4.7.2.9 Plastic film
0,05 mm thick x 50 mm x 50 mm, placed between the sample bottle cap and neck if the cap does not have
an internal seal. The film shall be compatible with both the cleaning and sample liquids.
4.7.2.10 Filter membranes
Preferred 25 or 47 mm in diameter, white, without grids, and compatible with the fluid to be analysed
and with the rinsing chemicals. Reference membranes shall have a recommended pore size of between
5 and 8 µm. The pore size used shall be stated.
4.7.2.11 Petri dishes
Of glass and 150 mm diameter.
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ISO 12345:2013(E)

4.7.2.12 Analytical balance
Of at least 0,05 mg accuracy.
4.7.2.13 Alpha-ray ionizer
To be used to prevent collection of dust during the weighing operation placed under the balance scale
incorporating the filter and projecting from beneath it.
4.7.2.14 Air dryer
4.7.2.15 Collecting vessel
A vessel with a vacuum device connecting, to be used to collect test fluid.
4.7.3 Microscopic analysis apparatus
NOTE For microscopic analysis see ISO 16232-7.
4.7.3.1 Filter membrane
Compatible with the sample liquid and any solvents or chemicals used in the processes. Normally,
the membrane shall be of 25 or 47 mm diameter, white, with grids (each grid square width side
3,08 mm ± 0,05 mm and equal to 1 % of the effective filtration area), and with a pore size < 8 µm, used
for manual counting down to 2 µm. A 47 mm diameter white, membrane without grids and with a pore
size of < 8 µm should be used for image analysis. Membranes of different diameters may be used.
4.8 Test fluid
4.8.1 General
Test fluids are described in the following clauses, depending on the test being conducted.
(see 5.2.2.1, 5.3.2, 5.4.2, 5.5.2.1, 5.5.3.1, 5.6.2.1, 5.7.2.1, 5.7.3.1, 5.7.4.1, 5.8.1, 5.8.3.1, 5.8.4.2, 5.9.2)
4.8.2 Calibration fluid
Test oil in accordance with ISO 4113, pre-filtered on a maximum of 1,0 µm cartridge filter, unless
otherwise specified.
4.8.3 Solvent, aliphatic hydrocarbon
Pre-filtered using a maximum of 1,0 µm, single-membrane nylon filter, which shall
— not leave any residue when vaporized, as residuals can influence the weighing results,
— have a minimum flash point of 38 °C, in order to fulfil normal working environment safety aspects,
— not have any aromatic components that could enter the atmosphere when vaporized, and
— have a boiling point not higher than 200 °C.
4.8.4 Water, de-mineralised
With surface tension reduction additives (e.g. Tensides) and pre-filtered on a maximum of 1,0 µm filter.
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ISO 12345:2013(E)

4.9 Clean-up filter
Cartridge filter with a filtration rating suited to the cleanliness level CL required for the test (see
Annex C).
4.10 Pressure gauge
Capable of measuring the system operating pressure, which is dependent on the system under test (see
5.3, 5.4, 5.5, 5.6 and 5.7).
5 Procedure
5.1 General
All tests should be carried out in a clean laboratory environment. Failure to achieve a satisfactory blank
test level of contamination could indicate unsuitable control of test conditions (see C.2). Clean room
conditions according to ISO 14644-1, class 8, shall be employed as a minimum for these procedures,
unless a suitable alternative can be demonstrated.
Before starting the test procedure the outer surface of the component or assembly should be thoroughly
cleaned by using a solvent such as detailed in 4.8.3.
This International Standard covers the following components of the fuel injection equipment:
a) Pumps:
1) high-pressure supply pumps (common rail fuel injection system) (see 5.2);
2) unit injectors (see 5.3);
3) fuel injection pumps (see 5.4);
b) Injectors:
1) CR fuel injectors (see 5.5);
2) fuel injectors (nozzle holder assemblies) (see 5.6);
c) Pipes and rails:
1) high-pressure fuel injection pipes (see 5.7);
2) rails (see 5.8);
d) Low pressure systems (see 5.9).
Each of these, in turn, is treated with respect to two procedural areas:
— equipment set-up and verification (the verification corresponds to the blank tests requested in
ISO 16232);
— testing procedure.
In cases where more than one test procedure for a component is specified, the experience has shown that
for removal of typical particles produced in the manufacture of these components, the test procedure
with a turbulent flow and with pulsating pressure (simulation method) is preferred, simulating actual
operating conditions.
When the simulation method is impractical, then the second test procedure should to be used as a more
pragmatic means for removal of contaminants.
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ISO 12345:2013(E)

If neither the simulation method nor the second test procedure prove practical to the supplier or
customer, by agreement a “flushing” test procedure (syringe or solvent dispenser method) may be used
as an alternative.
The determination of
— the test procedure to be used,
— as well as of the number of components to be tested,
— shall be by agreement between the fuel injection equipment supplier and customer.
5.2 High-pressure supply pumps (common rail fuel injection system)
5.2.1 General
This subclause describes two test procedures for checking the cleanliness of high-pressure supply
pumps:
— preferred test is a dynamic test with the test pump running;
— if the dynamic test is not practical, a flushing test at low speed with the test pump running by hand
should be used.
5.2.2 Dynamic test with the test pump running
5.2.2.1 Equipment set up and verification (blank test) of cleanliness
a) Set up the equipment for verifying the system as shown in Figure A.1 (see A.2.2, NOTE 3), using a
clean high-pressure supply pump of the same type as to be tested; the test bench shall have a separate
test reservoir for the calibration fluid. Instead of a clean pump a clean dummy or a hydraulic short
cut may be used.
b) The calibration fluid used should be as described in 4.8.2, pre-filtered using a filter as described in
4.9, permanently fixed in the system and replaced regularly.
c) Verify the system according to Annex C.
5.2.2.2 Test procedure
a) Replace the clean high-pressure supply pump by the pump to be tested; the pump shall be fully open
(any flow regulating devices or throttling devices are not active).
b) Connect a tube to the high-pressure outlet(s) and anoth
...

DRAFT INTERNATIONAL STANDARD ISO/DIS 12345
ISO/TC 22/SC 7 Secretariat: DIN
Voting begins on Voting terminates on

2010-12-14 2011-05-14
INTERNATIONAL ORGANIZATION FOR STANDARDIZATION  •  МЕЖДУНАРОДНАЯ ОРГАНИЗАЦИЯ ПО СТАНДАРТИЗАЦИИ  •  ORGANISATION INTERNATIONALE DE NORMALISATION


Diesel engines — Cleanliness assessment of fuel injection
equipment
Moteurs diesels — Évaluation de la propreté de l'équipement d'injection
[Revision of first edition (ISO 12345:2002)]
ICS 43.060.40










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REFERRED TO AS AN INTERNATIONAL STANDARD UNTIL PUBLISHED AS SUCH.
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©  International Organization for Standardization, 2010

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ISO/DIS 12345
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ii © ISO 2010 – All rights reserved

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ISO/DIS 12345
Contents Page
Foreword .v
1 Scope.1
2 Normative references.1
3 Terms and definitions .2
4 Test apparatus .3
4.1 General .3
4.2 Pressure source .3
4.3 Verification high-pressure pipe assembly.4
4.4 Verification test injector.4
4.5 Collecting vessel .4
4.6 Verification rail.4
4.7 Equipment for contamination measurement.4
4.8 Test fluid.6
4.9 Clean-up filter .7
4.10 Pressure gauge.7
5 Procedure.7
5.1 General .7
5.2 High-pressure supply pumps (common rail).8
5.3 Unit injectors.9
5.4 Fuel injection pumps.10
5.5 Common rail fuel injectors .11
5.6 Fuel injectors (Nozzle holder assemblies).13
5.7 High-pressure fuel injection pipes .14
5.8 Rails .16
5.9 Low-pressure systems.20
6 Sample analysis.21
6.1 General .21
6.2 Gravimetric analysis .21
6.3 Particle size distribution.21
6.4 Largest particle size.21
7 Reporting results.22
7.1 Principle of fuel injection equipment cleanliness code .22
7.2 Examples of fuel injection equipment cleanliness code usage. .23
8 Designation .24
Annex A (informative) Typical test equipment for measuring fuel injection equipment cleanliness.25
A.1 General .25
A.2 Basic principle of test equipment.25
A.3 Test equipment for syringe or hand flushing test .27
A.4 Test rig components for high-pressure supply pumps (test pump running by hand) .28
A.5 Rail pressure vessel flushing test (dynamic procedure) .29
Annex B (informative) Rail low pressure flushing test.30
Annex C (normative) Procedure for verifying test equipment initial cleanliness.31
C.1 Initial cleanliness verification procedures.31
C.2 Blank test .31
C.3 Criteria for acceptance.32
Annex D (informative) Determination of flushing parameters for rail pressure vessel flushing test.34
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ISO/DIS 12345
D.1 Blowhole and particle collection point. 34
D.2 Different flushing configurations to avoid blowholes and particle collection points . 34
Bibliography. 36

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ISO/DIS 12345
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 committee has been
established has the right to be represented on that committee. International organizations, governmental and
non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the
International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.
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.
ISO 12345 was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 7, Injection
equipment and filters for use on road vehicles.
This second edition cancels and replaces the first edition (ISO 12345:2002), which has been technically
revised.
Annex C forms a normative part of this International Standard. Annexes A, B and D are for information only.
© ISO 2010 – All rights reserved v

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ISO/DIS 12345
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

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 series relate to cleanliness of components used in Road
Vehicle fluid circuits, this Standard is focussed on diesel fuel injection assemblies as supplied to diesel engine
manufacturers or the service market.
2 Normative references
The following referenced documents are indispensable for the application of this document. 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 fluid 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, Compression ignition 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, Clean room and associated controlled environments – classification of air cleanliness
ISO 16232-6, Road vehicles — Cleanliness of components of fluid circuits — Part 6: Particle mass
determination by gravimetric analysis

ISO 16232-7, Road vehicles — Cleanliness of components of fluid circuits — Part 7: Particle sizing and
counting by microscopic analysis

ISO 16232-9, Road vehicles — Cleanliness of components of fluid circuits — Part 9: Particle sizing and
counting by automatic light extinction particle counter


SAE J 1549, Diesel fuel injection pump – Validation of calibrating nozzle holder assemblies
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ISO/DIS 12345
3 Terms and definitions
For the purpose of this International Standard, the following terms and definitions apply:
NOTE For terms and definitions given in ISO 4006, ISO 7876-1 to ISO 7876-5 and ISO 7967-7: see Bibliography.
3.1
Fuel injection equipment cleanliness code
FIECC
alpha-numeric code representing the distribution of particles by size and/or weight.
3.2
Cleanliness level
CL
amount and/or nature of contaminant present on the controlled surfaces and/or in controlled volumes of a
component
NOTE The term may apply to the presumed, specified or measured extent of contamination.
3.3
Cleanliness specification
CS
a document that specifies the cleanliness level CL required for a given component along with the agreed
inspection method
3.4
Reynolds number
Re
dimensionless parameter expressing the ratio between the inertia and viscous forces in a flowing fluid, given
by the formula
U×l
Re=
ν
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 millimetres
 [for pipes l = d (pipe bore diameter)]
ν  is the kinematic viscosity of the fluid, expressed in square millimetres per second [centistokes].
3.5
Blank Test
Analysis carried out with the same operating conditions as on the test component but without the component
or the component being a “clean” master sample used only for this purpose.
NOTE The blank test allows quantification of the contamination brought in from the environment, process or
materials used.
3.6
Blank value/ level
Result obtained from the blank test
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ISO/DIS 12345
4 Test apparatus
4.1  General
Typical test equipments recommended for measuring fuel-injection equipment cleanliness are described in
Annex A. Following are details of specific apparatus that may be used.
4.2  Pressure source
4.2.1 General
Take different forms for different tests, as described in the following subclauses.
4.2.2 Fuel injection pump test bench
A single cylinder inline pump as specified in SAE J1549 and a test bench as specified in ISO 4008-1.
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.
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.
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ISO/DIS 12345
4.3  Verification high-pressure pipe assembly
)
1
600 mm long, of tube ISO 8535-1 S-2-6-2 1 P 0 (see 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, while the pintle end may be removed to improve the particle passage.
+ 0 ,3
The nozzle opening pressure shall be set to 20,7    MPa.
− 0
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.
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 following specific laboratory apparatus.
4.7.2 Gravimetric analysis apparatus
NOTE For gravimetric analysis see ISO 16232-6.
4.7.2.1 Non-ventilated drying oven
Capable of maintaining a temperature of 80 °C ± 2 °C.

)
1
Use of stainless steel tubing is recommended to resist rust and corrosion contamination.
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ISO/DIS 12345
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 filter holder and of capacity enabling it to hold the entire volume of sample liquid without
refilling.
4.7.2.4 Vacuum device
Able to generate a vacuum of 86,6 kPa (gauge).
4.7.2.5 Solvent dispenser (syringe)
A pressurized vessel that discharges solvent through an in-line filter membrane with a pore size of not greater
than 1 µm.
4.7.2.6 Tweezers
Flat-bladed (non-serrated, blunt tips), and of stainless steel.
4.7.2.7 Graduated cylinders
For measuring out the volume of test liquid, to an accuracy that should be in accordance with ISO 4788.
Alternatively, a sample bottle calibrated with suitable volumetric graduations may be used, in which case the
accuracy of graduation should be ± 2 %.
4.7.2.8 Sample bottles
Of 250 ml nominal capacity, preferably flat-bottomed and wide-mouthed, with a screw cap containing a
suitable internal polymeric seal.
4.7.2.9 Plastic film
0,05 mm thick x 50 mm x 50 mm, placed between the sample bottle cap and neck if the cap does not have an
internal seal. The film shall be compatible with both the cleaning and sample liquids.
4.7.2.10 Filter membranes
Preferred 25 or 47 mm in diameter, white, without grids, and compatible with the fluid to be analysed and with
the rinsing chemicals. Reference membranes shall have a recommended pore size of between 5 and 8 µm.
The pore size used shall be stated.
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ISO/DIS 12345
4.7.2.11 Petri dishes
Of glass and 150 mm diameter.
4.7.2.12 Analytical balance
Of at least 0,05 mg accuracy.
4.7.2.13 Alpha-ray ioniser
To be used to prevent collection of dust during the weighing operation, placed under the balance scale
incorporating the filter and projecting from beneath it.
4.7.2.14 Air dryer
4.7.2.15 Collecting vessel
A vessel with a vacuum device connecting, to be used to collect test fluid
4.7.3 Microscopic analysis apparatus
NOTE For microscopic analysis see ISO 16232-7.
4.7.3.1 Filter membrane
Compatible with the sample liquid and any solvents or chemicals used in the processes. Normally, the
membrane shall be of 25 or 47 mm diameter, white, with grids (each grid square width side
3,08 mm ± 0,05 mm and equal to 1 % of the effective filtration area), and with a pore size < 8 µm, used for
manual counting down to 2 µm. A 47 mm diameter white, membrane without grids and with a pore size of < 8
µm should be used for image analysis. Membranes of different diameters may be used.
4.8  Test fluid
4.8.1 General
Test fluids are described in the following clauses, depending on the test being conducted.
(see 5.2.2.1, 5.3.2, 5.4.2, 5.5.2.1, 5.5.3.1, 5.6.2.1, 5.7.2.1, 5.7.3.1, 5.7.4.1, 5.8.1, 5.8.3.1, 5.8.4.2, 5.9.2)
4.8.2 Calibration fluid
Test oil in accordance with ISO 4113, pre-filtered on a maximum of 1,0 µm cartridge filter, unless otherwise
specified.
4.8.3 Solvent, aliphatic hydrocarbon
Pre-filtered using a maximum of 1,0 µm, single-membrane nylon filter, which shall
not leave any residue when vaporized, as residuals can influence the weighing results,
shall have a minimum flash point of 38 °C, in order to fulfil normal working environment safety aspects,
shall not have any aromatic components that could enter the atmosphere when vaporized, and
shall have a boiling point not higher than 200 °C.
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ISO/DIS 12345
4.8.4 Water, de-mineralised
With surface tension reduction additives (e.g. Tensides) and pre-filtered on a maximum of 1,0 µm filter.
4.9  Clean-up filter
Cartridge filter with a filtration rating suited to the cleanliness level CL required for the test (see Annex C).
4.10 Pressure gauge
Capable of measuring the system operating pressure, which is dependent on the system under test (see 5.3,
5.4, 5.5, 5.6 and 5.7).
5 Procedure
5.1  General
All tests should be carried out in a clean laboratory environment. Failure to achieve a satisfactory blank test
level of contamination could indicate unsuitable control of test conditions (see C.2). Clean room conditions
according to ISO 14644-1, class 8, are recommended as a minimum for these procedures.
Before starting the test procedure the outer surface of the component or assembly should be thoroughly
cleaned by using a solvent such as detailed in 4.8.3.
This International Standard covers the following components of the fuel injection equipment:
Pumps:
⎯ high-pressure supply pumps (common rail) (see 5.2)
⎯ unit injectors (see 5.3);
⎯ fuel injection pumps (see 5.4);
Injectors:
⎯ common rail fuel injectors (see 5.5);
⎯ fuel injectors (nozzle holder assemblies (see 5.6);
Pipes and rails:
⎯ high-pressure fuel injection pipes (see 5.7);
⎯ rails (see 5.8);
Low pressure systems (see 5.9).
Each of these, in turn, is treated with respect to two procedural areas:
⎯ equipment set-up and verification (the verification corresponds to the blank tests requested in ISO
16232);
⎯ testing procedure.
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ISO/DIS 12345
In cases where more than one test procedure for a component is specified, the experience has shown that for
removal of typical particles produced in the manufacture of these components, the test procedure with a
turbulent flow and with pulsating pressure (simulation method) is preferred, simul
...