TECHNICAL INFORMATION

DATE: 05/2019 ISSUE: 1 NUMBER: 11/646

SUBJECT: Bigger Capacity Fuel Filter Introduction

PRODUCTS AFFECTED: 220LC Xtra (2456601 - 2456800, 2543971 - 2544170, 2560101 - 2560600,
2738781 - 2739136)

TERRITORIES AFFECTED: India

SERVICE CODE: L360X REPAIR TIME: 5.00h

TO BE CARRIED OUT: information Only

SAFETY NOTICE: Instructions in Service Bulletins assume that the engineer has a sound knowledge of safety procedures and
has been trained in the maintenance and repair of JCB products. If you are unsure or do not understand information contained in
this or other bulletins, ask your supervisor or contact JCB Service for advice. REMEMBER SAFETY MUST COME FIRST.

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other
means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

This communication and the information within is intended for the recipient only, for information purposes, is confidential and may not be communicated to any third party.
Whilst the information is believed to be correct, no guarantee is given by JCB as to it’s accuracy and it’s use may not be attributed to JCB. This bulletin is issued for
information only and does not constitute an instruction to carry out warranty repairs on JCB products.

Introduction Figure 1. JCB220 New Fuel Line Layout

A B
Reports have been received on fuel pump and
injectors malfunction due to contamination observed
in fuel system. This bulletin refers to the new Fuel line
with a bigger capacity fuel filter introduction to further
improve its performance and avoid contamination
related issues.

To differentiate between new and current fuel line

layout.

1/6 11/646-1 1/6

 Figure 2. JCB220 Current Fuel Line Layout

E F

Table 1.
Filter Serial No. Action Filter Part No. Filter Element Part No. Filter Rating
A Added 320/A7130 320/07426 10µ
B Added 320/07482 320/07483 2µ
C Added 320/A7202 320/07416 2µ
D Deleted 320/A7060 32/925994 30µ
E Deleted 320/A7061 32/925869 5µ
F Deleted 320/A7062 32/925869 5µ
G Deleted 320/07309 320/ 07309 2µ

The above change has cut-in from machine serial 3. Make sure to collect any fuel spillage properly
number 2739137 onwards. and discard the same afterwards. Plug the tank
open ports to avoid contamination.
Service Instructions 4. Make access to the current filters and fuel line
installation. Remove the filters, fuel lines and
1. For machines before cut-in, a field fix kit is to be brackets. Keep these parts in a clean and safe
used for installation of new fuel line layout in the place for return to warranty.
event of fuel pump/injector failures, provided that
a proper warranty claim is raised with a mention 5. While removing these items, ensure to collect
of this TI Bulletin. any fuel spillage properly and discard the
same afterwards. Plug the open ports to avoid
2. Refer to parts list and service procedure as contamination.
mentioned in this bulletin for carrying out the field
fix. 6. Refer to below procedure for installation of new
fuel line layout. Follow general instructions as
3. For after cut-in machines, use new filters only below while referring to the kit child parts list:
during filter change service.
6.1. Stage 1 to Stage 4 filters to be assembled
4. Filters service schedule remains same for both separately. Refer to the below Figures.
before and after cut-in machines.
6.2. Keep items (marked as #) loose during
1st installation to make adjustments for
Procedure assembly at Stage 5 and tighten to specific
torque as mentioned.
1. Make the machine safe. Refer to the procedure
6.3. Use cable tie as required.
in the Operator's manual.
6.4. Use locking fluid as required and o not use
2. Arrange to drain and clean the diesel tank inside to tight lock nut.
area properly to make sure that it is free from
contamination.

2/6 11/646-1 2/6

 Figure 3. Stage 1 Figure 5. Stage 3 (Assembly from stage 2)

R P
H
J

L T

P Nut M12 Lock G12

H WA Filter MTG Bracket-2M Q Plain Washer M12
J Washer M10 R Adaptor: 1/8" NPT - SAE J2044 (16.9–19.7N·m)
K Set Screw M10 x 35 - G10.9 (60N·m) S Set Screw M12 x 40 - G10.9 (21N·m)
L Water Separator Assembly T ELP-H-6-C-2R-10CP-465-201
Figure 4. Stage 2 (Assembly from stage 1) Figure 6. Stage 4 (Assembly from stage 3)
N P

J
Q

P Nut M12 Lock G12

N Set Screw M10 x 30 - G10.9 (60N·m) Q Plain Washer M12
J Washer M10 S Set Screw M12 x 40 - G10.9 (21N·m)
M WA Filter MTG Bracket-10M U HDR-A-0-M-2B-02CP-387-218

3/6 11/646-1 3/6

 Figure 7. Stage 5 Figure 9. Stage 7
W V
X AA

AB

AA Nut M10 LOCK G12

Y Q
AB WA Filter MTG Bracket-4M
V Rubber Damper J Washer M10
W Plain Washer M8 N Set Screw M10 x 30 - G10.9 (60N·m)
X Set Screw M8 x 20 - G10.9 (30N·m)
Y Set Screw M12 x 30 - G10.9 (104N·m) Figure 10. Stage 8
Q Plain Washer M12
Figure 8. Stage 6 (Drill two holes)

K
Z
Z Filter Bracket WA (Existing) (333/J6056)
AC
J Washer M10
K Set Screw M10 x 35 - G10.9 (60N·m)
AC HDR-A-0-N-2R-04XP-240-111

4/6 11/646-1 4/6

 Figure 11. Stage 9 Figure 14. Stage 12

AS
Q
AL
AD AU

AK AH
AR

AE
AJ, AF, AM AD

AF, AM AR
AS WA Harness Clip
AU Set Screw M12 x 20 - G10.9
AH D/L Cable Tie
AH AG AR Fuel Hose 1,100mm 4m-ENG
AD Fuel Hose 1,325mm 2m-2m
AD Fuel Hose 1,325mm 2m-2m Q Plain Washer M12
AE Fuel Hose 525mm 10m-2m
AF Banjo Bolt 7. Arrange to fill the diesel tank and carry out air
AG Use Existing Fuel Hose (Tank to WS) bleeding for the entire fuel system. Refer to the
AH D/L Cable Tie Operator's manual for bleeding procedure.
AJ Fuel Hose 300mm - WS To Filter
AK Fuel Hose 550mm FLTR BYPS-TNK 8. Start the engine and check for any fuel leaks.
AL Vent Point Arrest if any.
AM Washer
9. Machine is now ready for use.
Figure 12. Stage 10
AN AP
Warranty Instructions
Table 2.
Service Code L360X
AK Description Fuel System Improve-
ment
AN Clip Wormdrive 8/16mm
AP Adaptor - 3/8" (9.5mm) Equal Tee Repair Time 5h
AK Fuel Hose 550mm FLTR BYPS-TNK Failed Part 320/A7060, 320/A7061,
320/A7062, 320/07309
Figure 13. Stage 11 Qty. 1 (each)
AD

AQ
AD Fuel Hose 1,325mm 2m-2m
AQ Mount Cable Tie

5/6 11/646-1 5/6

Parts List
Table 3.
Item Part No. Description Qty Remark
AX 336/F6038 Field Fix Kit JCB220Xtra New Fuel Line 1 Consists of items H to AV
(order this kit part number
only)
H 336/F1401 WA Filter MTG Bracket-2M 1
M 336/F1402 WA Filter MTG Bracket-10M 1
AB 336/F1403 WA Filter MTG Bracket-4M 1
V 336/E5476 Rubber Damper 1
L 333/Y6130 Water Separator Assembly 1
T 320/A7130 ELP-H-6-C-2R-10CP-465-201 1
U 320/07482 HDR-A-0-M-2B-02CP-387-218 1
AC 320/A7202 HDR-A-0-N-2R-04XP-240-111 1
AQ 123/00171 Mount Cable Tie 2 Tack weld to revolving
frame
AJ 401/F4307 Fuel Hose 300mm - WS To Filter 1
AF 03/305076 Banjo Bolt 2
AM 03/305077 Washer 4
AE 400/S5233 Fuel Hose 525mm 10m-2m 1
AD 400/S5272 Fuel Hose 1,325mm 2m-2m 1
AR 400/S5305 Fuel Hose 1,100mm 4m-ENG 1
AS 263/34900 WA Harness Clip 1
AU 1316/0505D Set Screw M12 x 20 - G10.9 1 Torque104N·m
AH 333/J8681 D/L Cable Tie 2
R 333/K3675 Adaptor: 1/8" NPT - SAE J2044 1 Torque16.9–19.7N·m
AP 333/K3492 Adaptor - 3/8" (9.5mm) Equal Tee 1
AK 401/B1855 Fuel Hose 550mm FLTR BYPS-TNK 1
AN 2201/0001 Clip Wormdrive 8/16mm 3 Torque2–2.5N·m
P 1371/0403D Nut M12 Lock G12 4
W 1420/0007D Plain Washer M8 2
Q 1420/0009D Plain Washer M12 8
Y 1316/0508D Set Screw M12 x 30 - G10.9 3 Torque104N·m
S 1316/0510D Set Screw M12 x 40 - G10.9 4 Torque21N·m
J JHP0046 Washer M10 8
K 1316/0409D Set Screw M10 x 35 - G10.9 4 Torque60N·m
N 1316/0408D Set Screw M10 x 30 - G10.9 4 Refer respective balloon
X 1316/0305D Set Screw M8 x 20 - G10.9 2 Torque30N·m
AA 1371/0303D Nut M10 LOCK G12 2
AV 826/01347 Cable Tie 160mm 10 Use as required
AW 4101/0500 Locking Fluid 0 Use as required. Do not
use to tight lock nut

6/6 11/646-1 6/6