16599

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 CONFIDENTIAL
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............................................................................................................................4
4. Specification ........................................................................................................................5
4.1. Significance and Use ...................................................................................................5
4.2. Acceptance Criteria......................................................................................................6
Table 1: Class Cleanliness Requirement.............................................................................7
5. Additional Requirements ...................................................................................................10
5.1. Residual Magnetism ..................................................................................................10
5.2. Laboratory Approval..................................................................................................10
5.3. Preproduction Parts....................................................................................................10
5.4. Packaging...................................................................................................................10
6. Reference Information .......................................................................................................10
Appendix A: Guidelines for Determination of Cleanliness Class and Test Method ...............11
Table A1: Table of Guidelines for Cleanliness Class and Test Method Application........12
Table A2: Table of Guidelines for Application of Test Methods......................................13
Table A3: Table of Suggested Drawing Notes by Example/Situation ..............................14
Appendix B: General Requirements Test Environment, Equipment, and Reagents ...............16
Table B1: Table of Equipment, Apparatus, and Reagent Requirements by Test Method.17
Appendix C: Test Method I Visual Inspection ........................................................................19
Appendix D: Test Method II (Flush and Brush)......................................................................20
Appendix E: Test Method III (Ultrasonic) ..............................................................................21
Appendix F: Test Method IV (Sprayed Parts Particle Counting) ............................................23
Appendix G: Test Method V (flowed fluid sample counting).................................................27

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1. Scope
This specification covers requirements for the cleanliness level of fuel systems components and
test methods.
2. Applicable Documents
Applicable documents listed below may be obtained from the respective organizations listed in
CES 10054, Standards Organizations Addresses.
a. ASTM D2276, Standard Test Method for Particulate Contaminant in Aviation Fuel by Line
Sampling
b. ASTM D3951, Standard Practice for Commercial Packaging
c. ASTM F312, Standard Test Methods for Microscopical Sizing and Counting Particles from
Aerospace Fluids on Membrane Filters
d. CES 10054, Standards Organizations Addresses
e. CES 10056, Glossary
f. CES16602, Residual Magnetism
g. ISO 3938, Hydraulic Fluid Power-Contamination Analysis-Method for Reporting Analysis
Data
h. ISO 4021, Hydraulic Fluid Power-Particulate Contamination Analysis-Extraction of Fluid
Samples from Lines of an Operating System
i. ISO 4406, Hydraulic Fluid Power-Fluids-Method for Coding the Level of Contamination
by Solid Particles
j. ISO 4407, Hydraulic Fluid Power-Fluid Contamination-Determination of Particulate
Contamination by the Counting Method Using an Optical Microscope
k. ISO 5884, Aerospace-Fluid Systems and Components-Methods for System Sampling and
Measuring the Solid Particle Contamination of Hydraulic Fluids
l. ISO 11217, Aerospace-Hydraulic System Fluid Contamination-Location of Sampling
Points and Criteria for Sampling
m. ISO 18413, Hydraulic Fluid Power-Cleanliness of Parts and Components-Inspection
Document and Principles Related to Contaminant Collection, Analysis and Data Reporting
n. SAE ARP 598, Aerospace Microscopic Sizing and Counting of Particulate Contamination
for Fluid Power Systems
o. SAE ARP 4285, Aerospace-Evaluation of Particulate Contamination in Hydraulic Fluid-
Membrane Procedure

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2. Applicable Documents (Continued)

p. SAE ARP 5376, Methods, Locations and Criteria for System Sampling and Measuring the
Solid Particle Contamination of Hydraulic Fluids
q. SAE J1227, Assessing Cleanliness of Hydraulic Fluid Power Components and Systems
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. Dried Filter Pad
Dried filter pad is a filter that has been kept in the drying oven for a minimum of 15 minutes at
150 + 5 °F (66 + 3 °C). Nominal pore size of the filter pad shall be smaller than the smallest particle
size to be counted/sized.
3.2. Superclean Solvent
Superclean solvent is Envirosolv 655 (or a part/assembly specific equivalent with documented
approval by the applicable Cummins Chief Engineer) filtered through a 1.0 micrometer or finer
filter. Superclean solvent for particle counting work should be at least 2 ISO 4406 scale numbers
cleaner than that of the cleanliness requirements of the component/fluid to be inspected.
3.3. Collection System
Pumps, filters, solvent reservoir(s), and a non corroding funnel mounted with a spray gun able to
pressurize/turbulently spray the superclean solvent at a known and controlled flow rate at 210 kPa
(30 psi) through a 2mm diameter nozzle/orifice onto/into parts and direct the part contacting fluid
through filter holding equipment. The following documents should be used as a guide to setting up
the system: ISO 18413 (Annex B), SAE ARP 4285, SAE J1227 (Parts Rinse test)
3.4. Particle Counting System
Setup to size and count the collected particles on the filter patches using a microscope. Use of an
automated microscope system with motorized stage, a digital camera, and image analysis software
is preferable. However less automated methods using gridded patches and an optical microscope
(i.e., as described in ISO 4407, ASTM F312, ISO 5884, and SAE ARP 598) are also applicable.

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3.5. Cognizant Engineering Organization
This term refers to the engineering organization within Cummins that has design authority over the
parts being processed.
3.6. Manufacturing Debris
Manufacturing debris includes machining chips, shot peen media, grit blast media, grinding/
polishing/honing media and any loose particle that may be detached during assembly or operation
of the component.
3.7. At Point of Assembly
This term refers to components to be assembled at the point of assembly.
3.8. As Received from Supplier
This term refers to components in the condition or state of arrival from an external (offsite)
supplier.
4. Specification
4.1. Significance and Use
4.1.1. This specification covers requirements for the cleanliness of fuel systems 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. Class cleanliness of the component.

b. Test method for collecting the sample.
c. Applicable surface area of the component in square millimeters.
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
• Alternate Criteria for As Received from supplier (if applicable)
f. Special fixturing (if required) to measure cleanliness shall be defined.

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4.1.2. (Continued)
g. For Test Method V, (if for other than for all operating conditions), assembly specific
operating/sampling conditions (i.e., fluid, flow rate, sample volume, conditioning prior to
sampling).
h. Alternate acceptance criteria (if applicable).
4.1.3. Guidelines for determination of cleanliness class and test method are in Appendix A:
Guidelines for Determination of Cleanliness Class and Test Method on page 11.
4.1.4. Test environment, equipment, and reagents shall be in accordance with Appendix B:
General Requirements Test Environment, Equipment, and Reagents on page 16.
4.1.5. The general procedure consists of the following steps:
a. Collecting the sample from the part(s) or fluid sample

b. Counting, measuring the numbers, sizes, and/or weight of particles on the filter pad
c. Evaluation of the test results
d. Accepting or rejecting the part(s)
e. Documentation of results
4.2. Acceptance Criteria
4.2.1. General Condition of Cleanliness-Classes

Parts shall be free from dirt, manufacturing debris, paint, grease, scale, grit, corrosion, and any
other foreign substance exceeding the requirements of Table 1: Class Cleanliness Requirement on
page 7. Heat temper film, corrosion inhibitors, coatings and marking/identification substances are
permitted if documented in a plan approved by the Cummins Supplier Quality Improvement
Organization. Components with corrosion inhibitors and coatings applied shall meet the applicable
cleanliness class, particle count, and particle size requirements.

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4.2.2. Class Cleanliness Requirements
Table 1: Class Cleanliness Requirement
Test Methods Class AA Class A Class B Class V
I Particles larger
(Appendix C) than 0.500 mm
shall not exceed
one particle per
500 mm2.
Particles larger
than 1.000 mm
shall not exceed
one particle per
2000 mm2.
II Particle size < 250 Particle size < 250 Particle size < 625
(Appendix D) µm X 125 µm. µm X 125 µm. µm X 375 µm.
Debris weight < Debris weight < Debris weight <

0.0001 mg/mm2 0.0001 mg/mm2 0.0003 mg/mm2
Maximum debris Maximum debris Maximum debris

for any size part = for any size part = for any size part =
4.0 mg. 6.5 mg. 6.5 mg.
Parts shall also Parts shall also Parts shall also

meet the Class V meet the Class V meet the Class V
Test Method I Test Method I Test Method I
cleanliness cleanliness cleanliness
requirements. requirements. requirements.

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Table 1: Class Cleanliness Requirement (Continued)
III Maximum particle Maximum particle Maximum particle

(Appendix E) size = 250 µm X size = 250 µm X size = 625 µm X
125 µm. 125 µm. 375 µm.

weight = 0.0001 weight = 0.0001 weight = 0.0003
mg/mm2 mg/mm2 mg/mm2

for any size part = for any size part = for any size part =
4.0 mg. 6.5 mg. 6.5 mg.
Parts shall also Parts shall also Parts shall also

meet the Class V meet the Class V meet the Class V
Test Method I Test Method I Test Method I

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Table 1: Class Cleanliness Requirement (Continued)
IV ISO 4406 scale ISO 4406 scale ISO 4406 scale

(Appendix F) numbers for the numbers for the numbers for the
average of 3 tests average of 3 tests average of 3 tests
for particle sizes for particle for particle sizes
(µm) 6/15/50/100/ sizes (µm) 6/15/50/ (µm) 6/15/50/100/
200/500 shall 100/200/500 shall 200/500 shall not
not exceed not exceed exceed 21/18/15/
14/12/9/7/4/0. Max 18/15/12/10/8/0. 12/11/1. Max
contaminant Max contaminant contaminant
weight: 0.0001 mg/ weight: 0.0001 mg/ weight: 0.0003 mg/
mm2 and not to mm2 and not to mm2 and not to
exceed 4.0 mg max exceed 4.0 mg max exceed 4.0 mg max
per part. Parts shall per part. Parts shall per part. Parts shall
also meet the Class also meet the Class also meet the Class
V Test Method I V Test Method I V Test Method I
V ISO 4406 scale ISO 4406 scale ISO 4406 scale
(Appendix G) numbers for the numbers for the numbers for the
average of 3 tests average of 3 tests average of 3 tests
for particle sizes for particle sizes for particle sizes
(µm) 6/15/50/100/ (µm) 6/15/50/100/ (µm) 6/15/50/100/
200/500 shall 200/500 shall not 200/500 shall not
not exceed exceed 18/15/12/ exceed 22/19/16/
14/12/9/7/4/0. 10/8/0. Maximum 14/12/1. Maximum
Maximum contaminant weight contaminant weight
contaminant weight per patch shall not per patch shall not
per patch shall not exceed 4.0 mg max. exceed 4.0 mg max.
exceed 4.0 mg max.

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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 approved by and be subject to disapproval by Cummins Supplier
Quality Improvement Organization.
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.
5.4. Packaging
Components shall be packaged and treated with appropriate corrosion prevention to ensure the
cleanliness level requirement is maintained during handling, storage and shipment. Packaging shall
conform to ASTM D3951 and shall be documented in a plan subject to disapproval by the
Cummins Supplier Quality Improvement Organization.
6. Reference Information
Envirosolv 655 is a product supplied by the following:
Fine Organics Corporation

205 Main Street
Lodi, NJ 07644
1-800-525-7480

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

These tables 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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(Continued)
Table A1: Table of Guidelines for Cleanliness Class and Test Method Application
Class AA Class A Class B Class V

“Exceptionally “Precision Clean” “Functional “Visually Clean”
Clean” Cleanliness”
Class For exceptionally For particularly Debris sensitive Parts that are not
Application debris sensitive debris sensitive components and in the unfiltered
components and components (more fluid contacting upstream fluid
associated debris sensitive components in the path of debris
components in than Class B) and unfiltered upstream sensitive parts.
the unfiltered fuel/oil wet of debris sensitive Typical
upstream. components in the components. components could
For individual unfiltered upstream Unless prior include fasteners.
components, Class of particularly experience or
AA should only be debris sensitive data indicates
applied where components. otherwise, this
Class A has been Typical cleanliness level
demonstrated to be components could should be
inadequate. include match fit selected/preferred
However, high plungers and over class A when
pressure pump barrels. the components
assemblies can need to be cleaner
generally be “run than visually clean.
in” to meet this Typical
requirement. components could
include tappets,
tappet springs, and
tappet spring
retainers.
Applicable II, III, IV, V II, III, IV, V II, III, IV, V I
Test
Methods

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(Continued)
Table A2: Table of Guidelines for Application of Test Methods
Test Method When to Apply
I
(Appendix D) For any part or assembly.
“Visual Inspection”
II Should not be used for new design but may be applicable for in-process
(Appendix G) control or for bought out finished components. For measurement of
“Flush and Brush” cleanliness of selected surfaces (i.e., internal passages of pump heads,
accumulators, etc.)
III Should not be used for new design but may be applicable for in-process
(Appendix H) control for bought out finished components. For measurement of
“Ultrasonic” cleanliness on all surfaces of the component.
IV Preferred inspection for validating the design requirements for

(Appendix E) cleanliness. For components where all surfaces to be evaluated are
“Sprayed Components” accessible.
V For complex parts or assemblies with internal passages where the

(Appendix F) cleanliness is desired in the internal passages, not necessarily on the
“Flowed Assemblies” external surfaces. Also applicable to flowed assemblies on a test stand.
Component specific operating conditions for the test method V sample
collection should be defined on the drawing. Operating conditions
should include fluid type, pressures, flow rate, vibration, timing of
sampling, and any other key operating parameters that could impact the
debris generation/liberation from the component.

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(Continued)
A2. Suggested/Template Drawing Notes

This table is for use as a guide/template for writing drawing notes:
Table A3: Table of Suggested Drawing Notes by Example/Situation
Example/Situation Example/Suggested Drawing Note(s) For the Situation
Bought out finished part supplied Inspection Standard CES 16599:
ready to assemble in the Class A, • Surface Area = Approx. xxx mm2
Test Method IV condition. • At Point of Assembly: Class A, Test Method IV.
Ready to assemble in the Class A Inspection Standard CES 16599:
Test Method IV condition. • Surface Area = Approx. xxx mm2
However, this part is intended to • As-Received: Class B, Test Method III
be supplied to all assembly plants • At Point of Assembly: Class A, Test Method IV.
in the Class B, Test Method III
condition.
Bought out finished part supplied Inspection Standard CES 16599:
ready to assemble in the Class A • Surface Area = Approx. xxx mm2
Test Method IV condition to all • At Point of Assembly: Class A, Test Method IV.
entities. However, this part may be • Applicable Receiving Entity Specific Alternate
supplied to FSP (Columbus) in the Criteria for As Received Components:
Class B, Test Method III condition
and may be supplied to JFS Receiving Entity Alternate Criteria for AS
(Juarez) in the Class V, Test Received from Supplier
Method I condition. FSP (Columbus) Class B, Test Method III
JFS (Juarez) Class V, test Method I
Bought out finished black/gray Inspection Standard CES 16599:

box assembly with limits on inlet • Inlet fluid shall not exceed Class B, Test Method V.
and outlet debris content (for all • Outlet fluid shall not exceed Class A, Test Method V.
operating conditions).

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(Continued)
A2. Suggested/Template Drawing Notes (Continued)

This table is for use as a guide/template for writing drawing notes:
Table A3: Table of Suggested Drawing Notes by Example/Situation (Continued)
Example/Situation Example/Suggested Drawing Note(s) For the Situation
Bought out finished black/gray Inspection Standard CES 16599:
box assembly with limits on outlet • Outlet fluid not to exceed Class A test Method V for:
debris content at a specified • List/Description of the operating condition
condition. parameters specified for the sample collection.

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Appendix B: General Requirements Test Environment, Equipment, and Reagents
B1. Testing requires an environment that will preserve the level of cleanliness for at least 48 hours
and would be satisfactory for operating high precision balances and microscope.
B2. Components that are intended for testing shall be handled with forceps or lint-free gloves.
Cleanliness level of parts for test shall be maintained prior to test and cross contamination of
groups of parts shall be avoided (i.e., by bagging/boxing individual parts or groups/samples of
parts for test).
B3. Equipment, Apparatus, and Reagent Requirements by Test Method
The following is a list of minimum equipment, apparatus, and reagent requirements by test
method.

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(Continued)
Table B1: Table of Equipment, Apparatus, and Reagent Requirements by Test Method
“X” Applies to
Test Method
Item
I II III IV V
a. Microscope and/or stereoscope with calibrated eye piece (capable of at X X X X X

least 40X magnification), adjustable lighting, and other features, as
needed, to determine/compare the dimensions of particles with the limits
of this specification.
b. Analytical laboratory balance capable of weighing filter pads to an X X X X
accuracy of plus/minus 0.1 mg and equipped with a shield door.
c. Mechanical vacuum pump capable of maintaining a vacuum on the filter X X X X
apparatus of 635 millimeters (25 inches) of mercury.
d. Drying oven capable of holding a temperature of 66 + 3 °C (150 + 5 °F). X X X X
e. Filter flask, not less than 0.5 L capacity. X X X X
f. Filter holder. X X X X
g. 5 micron rated nylon filters or equivalent that are compatible with solvent X X X X
and lint free.
h. Petri dishes, watch glass, or an equivalent containment method suitable X X X X
for storing used filter pads.
i. Stainless steel forceps and tongs suitable for handling filter pads and X X X X
tested components.
j. Ultrasonic cleaner with a frequency of 30-50 kHz. X

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(Continued)
Table B1: Table of Equipment, Apparatus, and Reagent Requirements by Test Method
(Continued)
“X” Applies to
Test Method
Item
I II III IV V
k. All equipment surfaces and apparatus that will be in contact with the X X X X
solvent of testing parts (brushes, trays, jars, pans, and such) shall be
capable of meeting class A cleanliness.
l. The brush material shall not be detrimental to the surface of the part. The X
diameter of the brush material shall be a minimum of 10 percent greater
than the hole it is being used to clean.
m. Solvent shall be in accordance with the following: X X X X
Petroleum Hydrocarbon
Surface tension is 18-22 dynes /cm at 25 °C
All metal safe
Specific gravity between 0.7-1.1 (water = 1) at 25 °C
Does not leave residue
Maximum of 0.1 mg of contamination per volume used for one test
Note: Envirosolv 655 is a recommended superclean solvent. Reclaimed
solvent shall not be used.
n. Collection System X X
o. Particle Counting System similar to or consistent with ISO 4406. X X
p. Superclean solvent should be at least 3 scale numbers cleaner/better than X X
the level indicated for the part/assembly to be assessed.

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Appendix C: Test Method I Visual Inspection
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 2000 mm2 for the test.
C2. Test Method
C2.1. The part shall be evaluated at a minimum of 10X magnification, with sufficient
illumination (> 800 lumens/m2 [75 foot-candles]).
C2.2. The test report/log/worksheet shall include (but not be limited to):
• Identification of the inspector

• Inspection date
• Drawing Number and Revision
• Parts/Sample Identifier (Something unique about this sample, i.e., lot/batch number,
treatment)
• Area (mm2) per part
• Number of pieces/parts checked
• Residual magnetism level(s) prior to inspection
• Raw Count/Size data
• Calculated number of particles per mm2 for each size range.
• Comments on conformance

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Appendix D: Test Method II (Flush and Brush)
D1. Sampling for test Method II shall be in accordance with the following:
a. The minimum number of parts “N” for the test shall be determined in accordance with the
formula:
N=0.003/Acceptance Limits for one part in grams
b. If N is less than 1, then one part shall be tested.

c. If N is greater than or equal to 20, then 20 parts shall be tested.
d. For example, if acceptance limit for one part is 0.0005 grams, then N=0.003/0.0005=6
e. parts. Therefore, 6 parts shall be tested.
D2. Test Method

D2.1. Only surfaces as specified on the engineering drawing or in-process documentation shall
be tested in accordance with this method.
D2.2. Parts shall be individually flushed and brushed.
D2.3. The surface as shown on the engineering drawing or in-process documentation shall be
flushed, brushed and rinsed at least twice with superclean solvent. Solvent shall be collected in a
clean sampling tray or equivalent.
D2.4. Collected solvent shall be filtered through the dried filter using a vacuum pump, dried
and evaluated.
D2.5. Filter shall be weighed before and after the test. The difference between the initial
weight of the filter pad and the final weight of the pad, divided by the number of parts in the test,
indicates contaminant level. The weight of the filter before and after the test, and the difference,
shall be recorded.
D2.6. Residue on the filter pad shall be examined using a microscope. Length and width of the
largest particle shall be recorded.
D2.7. Debris type shall be noted, i.e. metal shavings, metal fines, fibers or plastic.

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Appendix E: Test Method III (Ultrasonic)
E1. Sampling for test Method III shall be in accordance with the following:
a. The minimum number of parts “N” for the test shall be determined in accordance with the
formula:
N=0.003/Acceptance Limits for one part in grams
b. If N is less than 1, then one part shall be tested.

c. If N is greater than or equal to 20, then 20 parts shall be tested.
d. For example, if acceptance limit for one part is 0.0005 grams, then N=0.003/0.0005=6
e. parts. Therefore, 6 parts shall be tested.
E2. Test Method

E2.1. All beakers used for the test shall be cleaned with superclean solvent.
E2.2. Parts shall not be placed one on top of the other in the beaker.
E2.3. Parts shall be fully immersed in superclean solvent and ultrasonically cleaned in a sonic
cleaner. The level of the liquid in the sonic cleaner shall not be lower than the level of the solvent.
Components shall be uniformly spaced in the beaker. The following parameters shall be controlled
during this process:
a. Time: not less than 10 minutes.
b. Temperature: 70 to 90 ºF (21 to 32 ºC).
E2.4. Tested parts shall be removed from the beaker with forceps or tongs and rinsed into the
beaker using superclean solvent.
E2.5. The solvent shall be filtered through a dried filter. At the time of filtration the vacuum
pump shall be switched on. The beaker shall be rinsed with superclean solvent and the solvent
filtered along with the original sample.
E2.6. The filter shall be dried and prepared for evaluation.

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Appendix E: Test Method III (Ultrasonic) (Continued)
E2.7. Filter shall be weighed. The difference between the initial weight of the filter pad and
the final weight of the pad, divided by the number of parts in the test, indicates contaminant level.
The weight of the filter before and after the test, and the difference, shall be recorded.
E2.8. Residue on the filter pad shall be examined using a microscope. Length and width of the
largest particle shall be recorded.
E2.9. Debris type shall be noted, i.e. metal shavings, metal fines, fibers or plastics.

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Appendix F: Test Method IV (Sprayed Parts Particle Counting)
F1. Sampling
The minimum number of parts for each test shall be sufficient to provide a total part area of testing
exceeding 8500 mm2 for the test. Number of parts tested and debris loading of the parts tested shall
be such that the weight of debris on the filter pad does not exceed 4 milligrams.
F2. Test Method

F2.1. When drawings specify more than one set of Method IV acceptance criteria for a given
part/assembly (i.e., a more stringent acceptance criteria for internal surfaces than for external
surfaces), the drawing shall also reference/identify the part numbers/assembly numbers for the
drawings of the fixtures/masks to be used in association with the measurement.
F2.2. The superclean solvent spraying pressure at the 2 mm diameter spray gun exit orifice
(dead head) shall be 210 + 21 kPa (30 + 3 psi). The flow from the exit orifice of the spray gun shall
be so high that the flow of the spray stream becomes/is turbulent (broken up into droplets). The
operating conditions of the spray system shall be maintained and monitored to assure a consistent
(i.e., + 10%) rate of flow from the exit orifice of the spray gun. The rate of flow (i.e., ml/sec) 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).
F2.3. The filter pad size (i.e., 47 mm diameter) and type (i.e., Millipore 5.0 µm white SMWP)
used for the particle/debris collection shall be documented and controlled. Nominal pore size of the
filter pad shall be smaller than the smallest particle size to be counted/sized. Filter pads shall be
dried and weighed before use. Filter pads shall be allowed to reach room temperature before
weighing (~2 minutes).
F2.4. The suction pump below the collection system filter holder should be sized (relative to
the spray nozzle flow rate) to have sufficient capacity to minimize “ponding” of solvent above the
filter pad.

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Appendix F: Test Method IV (Sprayed Parts Particle Counting) (Continued)
F2.5. Background cleanliness of the superclean solvent and collection system shall be
determined, documented, and controlled. Spray times to be checked for the background
determinations should be similar to/consistent with the range of spray times being used for parts
tested. Background cleanliness of the collection system should be at least 3 scale numbers cleaner/
better than the level indicated for the part/assembly to be assessed. Reports/logs of background
cleanliness for the collection system shall include:
• Inspector
• Inspection date
• Collection system Equipment identifier
• Actual Solvent Temperature
• Actual filter pad type used (i.e., Millipore type SMWP 5.0 µm)
• Filter pad pre-weights and post weights
• Actual funnel/fixtures spray/wash time
• Actual drying oven temperature
• Count data file identifier
• Scale numbers for particles counted for each size range controlled by the cleanliness
class for which the collection system is used.
F2.6. 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. The minimum spraying time per part shall be
sufficient to deliver a minimum of 0.05 ml/mm2 to the part surfaces but not less than 20 seconds
per part. However, the total amount of fluid (for all parts in the test) shall be a minimum 0.5 liters
and maximum 20 liters.
F2.7. After individually spraying the part(s) for the required individual time(s), completely
spray the inside of the funnel (and any internal funnel fixturing) and part(s) for ~ 30 seconds to
wash as much as possible of the debris liberated from the part(s) down into the collection filter pad.
Then allow at least 30 seconds “drip down” time before disturbing/removing the filter pad.
F2.8. After the dirt from the part is collected on the pre weighed filter pad, the filter pad shall
be dried in a drying oven at a controlled temperature for at least 15 minutes and reweighed (after
cooling to room temperature for ~2 minutes).

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Identifier
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F2.9. After drying, the sizes and numbers of particles on the filter pad shall be measured/
counted/calculated using the particle counting system for every particle size category given in the
specified cleanliness class requirement.
F2.10. Statistical counting (i.e., as described in ISO 4407) shall utilize counting/sizing of at
least 150 particles over a total of at least 10 separate locations (fields). Area extrapolation shall be
in accordance with ASTM F312.
F2.11. The particle concentration K (number of particles per ml) is calculated for every
particle size given in the specified cleanliness class requirement. The value of K shall be used with
ISO 4406 to determine the scale number for comparison with the cleanliness class requirements.
The particle concentration K shall be obtained from the following equation:
K = S ⁄ ( A*G )
Where
S = Number of particles in the size category on the filter pad.
A = Total area (mm2) of parts subject to the requirements present in the test used to generate the
patch. (I.e., if 3 parts each having an area of 300 mm2 were used in the test, then A would be 900
mm2).
G = The total fluid volume (ml) of the system (that uses the part/assembly) divided by the total area
of surfaces exposed to the system fluid (mm2). (Use G = 0.002 ml/mm2 for fuel systems parts/
assemblies.)
F2.12. Record/report the particle counts based on the K values in accordance with ISO 4406
for the particle sizes controlled by the applicable cleanliness class.
F2.13. After counting, the filter pads shall be preserved in a manner that permits recounting
for a period of time approved by the Cummins Supplier Quality Improvement Organization.

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Identifier
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F2.14. The test report/log/worksheet shall include (but not be limited to):
• Inspector
• Inspection date
• Parts/Sample Identifier (Something unique about this set of parts, i.e., lot/batch number,
treatment)
• Number of pieces tested
• Collection System Equipment identifier
• Residual Magnetism Level(s) of the parts prior to test.
• Nominal spray time per part
• Filter pad pre weights and post weights
• Weight of debris on the filter pads (post weight-pre weight)
• Raw/extrapolated/calculated Counts for each size range for the patch (S values)
• G value used
• Calculated K values for each size range.
class called by the drawing.

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Identifier
(ITEM)
Appendix G: Test Method V (flowed fluid sample counting)
G1. Sampling
Sampling for test Method V shall be in accordance with the following: The fluid volume for the
test shall exceed 475 ml. The nominal volume of fluid for the test should be approximately 500 ml.
Volume of fluid tested and debris loading of the fluid tested shall be such that the weight of debris
on the filter pad does not exceed 4 milligrams.
G2. Test Method

G2.1. A sample (preferably of known volume, Vol) of the fluid of interest is collected into a
clean/inert container while the component of interest is being flushed/operated under specified/
documented conditions. In general, the flushing/operating conditions for sampling should be
selected/specified to maximize debris generation/release from the component. The following
documents should be considered as guides to detailing/documenting and specifying sample
collection practices for the particular component: ISO 18413, SAE ARP 5376, ISO 4021,
ASTM D4174, ASTM D2276, ISO 11217, ISO 5884.
G2.2. The fluid sample is agitated/mixed and a measured/known volume Vol of the fluid is
filtered through a pre weighed filter pad in a collection system. After the fluid sample has been
filtered, the affected upstream surfaces of the collection system shall be rinsed down into the filter
using superclean solvent before removing the filter pad.
G2.3. After the particles from the fluid sample are collected on the pre weighed filter pad, the
filter pad shall be dried in a drying oven at a controlled temperature for at least 15 minutes and
reweighed. Filter pads shall be allowed to reach room temperature before weighing (~2 minutes).
G2.4. After drying, the sizes and numbers of particles on the filter pad shall be measured/
counted/calculated using the particle counting system for every particle size category given in the
specified cleanliness class requirement.
G2.5. Statistical counting (i.e., as described in ISO 4407) shall utilize counting/sizing of at
least 150 particles over a total of at least 10 separate locations (fields). Area extrapolation shall be
in accordance with ASTM F312.

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Identifier
(ITEM)
Appendix G: Test Method V (flowed fluid sample counting) (Continued)
G2.6. The particle concentration K (number of particles per ml) is calculated for every particle
size given in the specified cleanliness class requirement. The value of K shall be used with
ISO 4406 to determine the scale number for comparison with the cleanliness class requirements.
The particle concentration K shall be obtained from the following equation:
K = S ⁄ Vol
Where
S = Number of particles in the size category on the filter pad.
Vol = Volume (ml) of the fluid tested.
G2.7. Record/report the particle counts based on the K values in accordance with ISO 4406 for
the particle sizes controlled by the applicable cleanliness class.
G2.8. After counting, the filter pads shall be preserved in a manner that permits recounting for
a period of time approved by the Cummins Supplier Quality Improvement Organization.
G2.9. The test report/log/worksheet shall include (but not be limited to):
• Inspector
• Inspection date
• Parts/Sample Identifier (Something unique about this sample, i.e., lot/batch number,
treatment)
• Volume tested
• Collection System Equipment identifier
• Filter pad pre weights and post weights
• Weight of debris on the filter pads (post weight-pre weight)
• Raw/extrapolated/calculated Counts for each size range for the patch (S values)
• Calculated K values for each size range.
class called by the drawing.

042020-076 005 Page 28 of 28

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INSPECTION SPECIFICATON 16599

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Heading Page Number

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2. Applicable Documents (Continued)

3.1. Dried Filter Pad

3.2. Superclean Solvent

3.3. Collection System

3.4. Particle Counting System

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3.5. Cognizant Engineering Organization

3.6. Manufacturing Debris

3.7. At Point of Assembly

This term refers to components to be assembled at the point of assembly.

3.8. As Received from Supplier

a. Class cleanliness of the component.

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4.1.5. The general procedure consists of the following steps:

a. Collecting the sample from the part(s) or fluid sample

4.2. Acceptance Criteria

4.2.1. General Condition of Cleanliness-Classes

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4.2.2. Class Cleanliness Requirements

Table 1: Class Cleanliness Requirement

Test Methods Class AA Class A Class B Class V

Debris weight < Debris weight < Debris weight <

Maximum debris Maximum debris Maximum debris

Parts shall also Parts shall also Parts shall also

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Table 1: Class Cleanliness Requirement (Continued)

Test Methods Class AA Class A Class B Class V

III Maximum particle Maximum particle Maximum particle

Maximum debris Maximum debris Maximum debris

Maximum debris Maximum debris Maximum debris

Parts shall also Parts shall also Parts shall also

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Table 1: Class Cleanliness Requirement (Continued)

Test Methods Class AA Class A Class B Class V

IV ISO 4406 scale ISO 4406 scale ISO 4406 scale

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5.2. Laboratory Approval

5.3. Preproduction Parts

Fine Organics Corporation

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Appendix A: Guidelines for Determination of Cleanliness Class and Test Method

A1. Cleanliness Class

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INSPECTION SPECIFICATON 16599

Appendix A: Guidelines for Determination of Cleanliness Class and Test Method

Class AA Class A Class B Class V

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